Precharge manifold system and method

A pulsation dampener system is provided. The pulsation dampener system includes a pump that pumps fluid through the pulsation dampener system. A pulsation dampener is located downstream from the pump and dampens pulsations within the fluid. A pressure sensor is located downstream from the pump and detects a pump pressure of the fluid at the pulsation dampener. A wye pipe located downstream of the pulsation dampener and the pressure sensor that diverts the fluid into two or more flow paths. From the wye, a first flow path increases pump pressure of the fluid and a second flow path allows the fluid to flow unrestricted. Piping receives the fluid from the first flow path and the second flow path and discharges the fluid further downstream.

TECHNICAL FIELD

The present application relates generally to the operation of fluid transfer systems and, more specifically, to providing a precharge manifold decrease ramp-up time in a fluid transfer system.

BACKGROUND

Fluid transfer systems circulate fluid from a pump to downstream equipment. Pulsations within the fluid can deteriorate the integrity of the pump and that of other equipment downstream from the pump. Pulsation control is the process of reducing pulsations within the fluid of a fluid transfer system. Reducing pulsations within a fluid transfer system can increase the longevity of the equipment as well as the efficiency of the overall system. Among the improvements desirable are reduced pulsation amplitudes from pumps to the downstream system and greater flexibility in integration of pulsation dampeners with other elements of an overall pump system.

A pulsation control device is designed to reduce pulsations in a fluid transfer system based on parameters of the fluid transfer system while the system is fully operational. During various periods of operation, such as while the fluid transfer system is ramping up or ramping down, the fluid transfer system might operate under different parameters and as such, the pulsation device does not perform at the peak efficiency. Therefore, there is a need for improved control to ensure that a pulsation control device performs under near operational status during period of when the system is not actually under fully operational conditions.

SUMMARY

In one aspect thereof, a pulsation dampener system includes a pump that pumps fluid through the pulsation dampener system and a pulsation dampener, located downstream from the pump, for dampening residual pulsations within the fluid. The system also includes a wye pipe located downstream of the pulsation dampener that splits the fluid into two or more flow paths. A first flow path for the fluid is located at the wye, wherein the first flow path and increases the pressure of the fluid. A second flow path for the fluid is located at the wye, that allows the fluid to flow unrestricted. The system also includes piping that receives the fluid from the first flow path and the second flow path and discharges the fluid further downstream. The system also includes a pressure sensor located upstream of the wye pipe and configured to detect the pressure of the fluid at the pulsation dampener. The system also includes a second sensor or some user supplied monitor downstream of the Wye to monitor system pressure.

In another aspect thereof method for dampening pulsation includes receiving fluid from a pump. The method also includes dampening pulsations in the fluid, using a pulsation dampener. The method further includes detecting a pressure of the fluid at the pulsation dampener. The method also includes splitting the fluid into two or more paths downstream of the pulsation dampener, the two or more paths include a first flow path and a second flow path. Additionally, the method includes increasing the pressure of the fluid, when the fluid flows through the first flow path.

DETAILED DESCRIPTION

Reciprocating systems, such as reciprocating pump systems and similar equipment, operate in many types of cyclic hydraulic applications. For example, reciprocating mud pump systems are used to circulate the mud or drilling fluid on a drilling rig. Pressure peaks as well as the magnitude of pressure pulsations within the pumped fluid hasten the deterioration of the pump, the pump's fluid end expendable parts, and equipment downstream from the pump, such as measurement equipment used to determine drilling parameters. Failure to control such pressure peaks and the magnitude of the pulsation inevitably affects the operating performance and operational life of the pump, pump fluid end expendable parts and all upstream or downstream components. Additionally, pressure peaks as well as the magnitude of pressure pulsations within the pumped fluid can interfere with instrument signal detection and/or quality of the signal detection.

Pulsation control equipment is typically placed immediately upstream or downstream from a reciprocating pump. Pulsation control equipment aids in reducing pump loads and minimizing pulsation amplitudes to the pump, the pump's fluid end expendable parts, and to equipment upstream or downstream from the pump. As a result, pulsation control equipment increases the relative operating performance and life of the pump, the pump's fluid end expendable parts, and any equipment upstream or downstream from the pump. The size and configuration of pulsation control equipment is proportional to the volume of desired fluid displacement per stroke of the pump and the maximum allotted magnitude of the pressure peaks and magnitude of the pressure pulsations that may be experienced by the pump system during each pulsation.

Different pulsation dampening systems have been developed. Common types of pulsation dampeners are a hydro-pneumatic dampener, or a gas-charged pressure vessel. A gas-charged pressure vessel contains compressed air or nitrogen and a bladder or bellows that separates the process fluid from the gas charge. A gas-charged pressure vessel can be cylindrical or roughly spherical shaped. Gas-charged pulsation dampeners may be either flow through or appendage type devices. To optimize the pulsation dampening effect, it is often preferable that the pulsation dampener be installed as close as possible to the pump discharge. At such locations, however, the presence of the pulsation dampener may interfere with installation of other system components, such as a strainer.

Regardless of the type of dampener, the performance of a pulsation dampener diminishes when the pressure of the fluid from the pump is too far from the gas precharge pressure range that the dampener is designed to handle. For example, the gas-charged pulsation dampener design typically requires the gas precharge pressure be slightly below the system pressure during normal operations, and that the pulsation dampener be properly sized for the system. Even when a pulsation dampener is installed in a drilling system, pulsations may be experienced further downstream from the pumps when the pulsation dampener is not properly sized or precharged for the system. For example, an undersized dampener cannot adequately compensate for pressure and flow fluctuations, while an oversized dampener will act as an accumulator, storing too much fluid and causing slow stabilization and delayed response to system changes. Another example is the dampener precharge pressure is too high for the system pressure, thus the system pressure cannot compress the discharge dampener precharge pressure to engage the gas to allow pulsation control to take place. When the pressure of the fluid within the pipeline is ramping-up to a pressure suitable for the drilling operation (which corresponds to a proper sized pulsation dampener), the pulsation dampener can be considered oversized since the pressure of the fluid is less than the pressure that is suitable for drilling operations. As a result, pulsations can progress downstream, since the pulsation dampener is oversized during the ramp-up period. These downstream pulsations can cause damage to the various downstream components (both equipment and sensors), increased audible noise, increase noise in sensor readings related to the drilling operation, and reduce performance of the drilling operation, when the pressure of the system is not within the pressure range the pulsation dampener is designed to handle.

FIG. 1illustrates a simplified cross-sectional and somewhat schematic view of a reciprocating pump system100employed within a pulsation dampener system with multiple flow paths, according to an embodiment of the present disclosure. Generally, the reciprocating pump system100includes a pump suction and/or discharge pulsation control product including a gas-charged pulsation dampener or a reactive pulsation dampener according to an embodiment of the present disclosure. The reciprocating pump system100may employ a reciprocating pump of a type well-known and commercially available. The pump within the reciprocating pump system100is configured to reciprocate one or more plungers or pistons101(only one shown inFIG. 1). Each piston or plunger is preferably connected by a suitable rotatable crankshaft (not shown) mounted in a suitable “power end” housing102. Power end housing102is connected to a fluid end structure103configured to have a separate pumping chamber104for each piston or plunger101. Pumping chamber104is exposed to its respective piston or plunger101. One such chamber104is shown inFIG. 1.

More specifically,FIG. 1illustrates a simplified cross-sectional view through a typical pumping chamber104. Fluid end103includes housing105. Pumping chamber104receives fluid from inlet manifold106by way of a conventional poppet type inlet or suction valve107(only one shown). Piston or plunger101, projecting at one end into chamber104, connects to a suitable crosshead mechanism, including crosshead extension member106. Crosshead extension member106is operably connected to a crankshaft or eccentric (not shown) in a known manner. Piston or plunger101also projects through a conventional liner or through conventional packing109, respectively. Each piston or plunger101is preferably configured to chamber104. Each piston or plunger101is also operably connected to inlet manifold106and discharge piping manifold110by way of a suitable suction valve107or discharge valve111, as shown. Inlet manifold106can include a suction piping manifold that typically receives fluid from suction stabilizer (not shown inFIG. 1) or a suction piping with a suction stabilizer. Discharge piping manifold110typically discharges into a discharge dampener (not shown inFIG. 1). Valves107and111are of conventional design and typically spring biased to their respective closed positions. Valves107and111each also may include or be associated with removable valve seat members112and113, respectively. Each of valves107and111may preferably have a seal member (not shown) formed thereon to provide fluid sealing when the valves are in their respective closed and seat engaging positions.

Those skilled in the art will recognize that the techniques of the present disclosure may be utilized with a wide variety of single and multi-cylinder reciprocating piston or plunger power pumps as well as possibly other types of positive displacement pumps. As one example, the number of cylinders of such pumps may vary substantially between a single cylinder and essentially any number of cylinders or separate pumping chambers. Those skilled in the art will also recognize that the complete structure and operation of a suitable pump system is not depicted or described herein. Instead, for simplicity and clarity, only so much of a pump system as is unique to the present disclosure or necessary for an understanding of the present disclosure is depicted and described.

Conventional pump systems, such as the reciprocating pump system100shown inFIG. 1, typically include a dampener system.FIG. 2illustrates a simplified dampener system200. The dampener system200is a cross sectional view of a typical pulsation dampener205, according to an embodiment of the present disclosure. Pulsation dampener system200includes a pulsation dampener205affixed to a pipeline212. The pulsation dampener205includes a diaphragm202, a liquid chamber204containing a liquid, a gas pressure chamber206containing a gas, and an inlet210.FIG. 2does not limit the scope of this disclosure to any particular implementation of a drilling system.

Pulsation dampener205dampens low frequency pulsations and pressure pulsations by reducing the lower frequency energies created by the pumping actions. Pulsation dampener205dampens pulsations contained within the fluid flowing through the pipeline212. In certain embodiments, pulsation dampener205is located above the pipeline212.

Pulsation dampeners, such as the pulsation dampener205, are either directly attached to the discharge manifold110ofFIG. 1, or located downstream of the pump. Generally, the pulsation dampener205receives “fluid” (which may be entirely liquid or which may include suspended solids—i.e., a slurry) at an inlet210. The inlet210can be connected to the discharge piping manifold110of the reciprocating pump system100ofFIG. 1either directly or by intervening piping (not shown). The connection allows pumped fluid to enter the liquid chamber204, via the inlet210, of the pulsation dampener205.

Fluid enters and exits the liquid chamber204via the inlet210. The gas pressure chamber206is filled with pressurized gas to a predefined pressure, known as precharge. In certain embodiments, the pressurized gas is nitrogen (N2) or another gas. A diaphragm202separates the gas pressure chamber206from the liquid chamber204. The pressurized gas in the gas pressure chamber206minimizes pressure variation of the fluid by absorbing system shocks, pipe vibration, water hammering, pressure fluctuations, and the like. By minimizing pulsation in the system, the longevity of various components such as regulators, pumps, valves, sensors, and so forth is increased since wear on the components caused by the pulsations is reduced.

As the fluid passes into the liquid chamber204pressure from the liquid can be exerted on the diaphragm202causing the diaphragm202to compress the gas within the gas pressure chamber206. When the pressure of gas within the gas pressure chamber206is increased, the gas occupies less volume, thereby increasing the volume of the liquid chamber204. Pulsations within the fluid are then dispersed across the volume of the pressurized gas in the gas pressure chamber206. The volume and subsequent pressure of the gas in the gas pressure chamber206increases and reduces in response to pressure variances of the fluid. For example, as the pressure of the fluid within the pulsation dampener205fluctuates, the gas in the gas pressure chamber206compresses thereby decreasing the pressure variance and pulsations within the fluid flowing through the pipeline212. That is, by increasing and decreasing the volume of the gas within the gas pressure chamber206, the amount of pressure variation in the fluids contained within the liquid chamber204and the pipeline212are reduced. The pressure pulsations of the fluid are reduced, if not negated, by increasing and decreasing the volumes of the gas within the gas pressure chamber206. When the precharge pressure is near the system pressure, performance of the pulsation dampener205is improved.

The fluid that enters the liquid chamber204is affected by the pressure changes within the fluid. The pressure changes within fluid cause the diaphragm202to move, which in turn compresses and decompresses the gas in the gas pressure chamber206. Compressing and decompressing the gas in the pressure chamber206dampens the pulsations within the fluid. For example, when energy from the pulsations within the fluid is transferred to the gas in the pressure chamber206, the gas compresses, absorbing the pressure spikes from the fluid.

The precharge pressure of the gas within the gas pressure chamber206is preset. The precharge pressure is dependent on the anticipated pump discharge pressures (also referred to as the pump pressure) of the system. For example, if the pump discharge pressure is 5,000 pounds per square inch (PSI), then the precharge pressure of the gas is less than 5,000 PSI. However, if the precharge pressure is too low (in comparison to the pump discharge pressure), then the pulsation dampener205does not sufficiently dampen the flow of the fluid and internal damage can occur to components downstream as well as the dampener205itself. That is, when the pump discharge pressure of the fluid compresses the precharge gas beyond a threshold, the volume of the precharge gas occupied within the discharge dampener is negligible. Additionally, the bladder containing the pressurized gas, within the gas pressure chamber206, can sustain damage from impact or it can become ‘unseated.’ Alternatively, if the precharge pressure is the same or higher than the pump discharge pressure then the pulsation dampener205does not perform any dampening.

When the pump is ramping up for a drilling operation, the current pump discharge pressure is less than the intended downstream system pressure (also referred to as system pressure) while under drilling operations. Consequently the pulsation dampener205does not perform any dampening, as its internal gas charge pressure could be higher than the current pump discharge pressure of the drilling system. Only after the internal pressure of the pulsation dampener205(which is often fixed) is less than the current pump discharge pressure, does the pulsation dampener205dampen pulsations within the fluid. It is noted that the pump discharge pressure is the pressure of the fluid as it is discharged from the pump, upstream of the orifice, and the downstream system pressure is the pressure of the fluid downstream of the orifice.

FIG. 3Aillustrates diagrammatic view of a pump dampener system300including a pulsation dampener installed between a pump and a multiple flow paths, according to various embodiments of the present disclosure.FIG. 3Adoes not limit the scope of this disclosure to any particular embodiments of a precharge manifold system.

The pump dampener system300reduces pressure pulsation generated by the pumping motion of pump310. The pump dampener system300is design to increase a pressure of the fluid during ramp-up operations, thereby dampening pressure pulsations earlier. The pump dampener system300is located before a drilling rig or system that requires a pumped fluid for operating. Pump dampener system300includes at least one pump310(similar to the reciprocating pump system100ofFIG. 1), at least one pulsation dampener312(similar to the pulsation dampener system200ofFIG. 2), at least valves320,322, and324, at least pipelines302A,302B,302C,302D, and302E as well as at least one flow restricting device, such as an orifice326.

Pipelines302A,302B,302C,302D, and302E represent conduit type tube to convey the fluid for the drilling operation from a first location to a second location. The pump dampener system300can encompass a plurality of pipelines and is not limited to pipelines302A,302B,302C,302D, and302E. Pipelines302A,302B,302C,302D, and302E can be made of various materials (such as steel or aluminum) and strong enough to withstand the internal pressures of the fluid from the drilling operation.

The pump310can be a reciprocating pump or another type of device that causes pulsations in fluids be transferred through a pipeline. The pump310is connected to a reservoir or other fluid containing system to move the fluid in the reservoir downstream through pipeline302A. In certain embodiments, pump310represents a plurality of pumps connected to a plurality of pipelines302A.

In certain embodiments, pulsation dampener312is connected to pump310via pipeline302A. For example, pipeline302A is attached to the discharge piping manifold of pump310(similar to discharge piping manifold110ofFIG. 1) and the intake piping manifold of pulsation dampener312(similar to inlet210ofFIG. 2). In another embodiment, pulsation dampener312is directly connected to pump310, and pipeline302A is omitted. In certain embodiments, pulsation dampener312represents a plurality of pulsation dampeners.

In certain embodiments, pipeline302A includes a pressure sensor315to detect the pump pressure of the fluid leaving the pump310and entering the pulsation dampener312. The pump pressure is important for determining the efficiency of the pulsation dampener312. The pulsation dampener312is “precharged” at a certain pressure level to be optimized at the operating pressure of the fluid discharged. The efficiency of the pulsation dampener312is greatly reduced when the pressure of the fluid in the pipe is below the precharge pressure of the pulsation dampener312.

The pulsation dampener312is also connected to the wye pipe303via pipeline302b. Based on the reading from the pressure sensor315the pump dampener system300determines whether the pulsation dampener312will dampen pulsations from the pump310. For example, based on the precharge pressure of the pulsation dampener312coupled with pump pressure of the fluid (as indicated by the pressure sensor315), the pulsation dampener312may or may not dampen pulsations within the fluid. The pump pressure is defined as the pressure of the fluid before the wye pipe303. The pump pressure is measured to determine the pressure of the fluid at the pulsation dampener312.

In certain embodiments, pipeline302B includes a pressure sensor (not shown) to detect the pressure of the fluid leaving the pulsation dampener312and entering the wye pipe303. In certain embodiments, the pressure sensor315is located along pipeline302B instead of pipeline302A, as depicted.

When pump310is running, during a drilling operation, at its scheduled PSI, pump310transmits fluid into the fluid chamber (similar to liquid chamber204ofFIG. 2) of pulsation dampener312. The pulsation dampener312can include a diaphragm (similar to the diaphragm202ofFIG. 2), and/or a pressure chamber (similar to the gas pressure chamber206ofFIG. 2). Fluid entering the pulsation dampener312can contain unwanted pressure pulses and pulsations. Once the fluid is within the pulsation dampener312, pulsations can be transmitted to the gas within the pressure chamber, dependent on various parameters such as the precharge pressure of the gas within the pressure chamber and the pump discharge pressure of the drilling operation. The pulsation dampener312is selected to match the operating output pressure from the pump310. For example, if the pressure of the fluid in the pipeline is at 5,000 PSI, then the gas chamber within the pulsation dampener312could be precharged to a comparable pressure, such as 2,500 PSI, to reduce low frequency pulsations, pressure pulsations as well as reduces the lower frequency energies created by the pumping actions.

Typically, the fluid leaves the pulsation dampener312via pipeline302B and continues through additional components and equipment used in a drilling operation (not shown inFIG. 3A).

Embodiments of the present disclosure recognize and take into consideration that when pump310is ramping-up at the start of a drilling operation or any other low pressure occurrence during the drilling operation, the output pressure from the pump310can be less than or equal to the precharge gas pressure set for the pulsation dampener312. When the pressure in the pipeline is less than the precharge gas pressure or designed pressure of the pulsation dampener312, the ability of the pulsation dampener312to reduce pulsations is decreased as the gas chamber of the pulsation dampener312is over-pressurized as compared to the pressure of the fluid moving within the fluid chamber of the pulsation dampener312. The greater the difference between the pressure in the pipeline as compared to the pressure in the gas chamber of the pulsation dampener312the effectiveness of the pulsation dampener312to reduce pulsations is reduced.

Embodiments of the present disclosure provide that pipeline302B diverts into at least two separate flow paths, to create multiple flow paths of the fluid. In certain embodiments, the split is a wye pipe303. In certain embodiments, the wye pipe303is a traditional wye fitting. Wye pipe303could represent any type of pipe fitting that can diverge the pressurized the fluid into multiple paths or directions such as, a diverter tee, a tee fitting, or a cross fitting, to name a few. Pump dampener system300illustrates pipeline302B splitting into pipeline302C and pipeline302D. By utilizing multiple flow paths, where at least one of the flow paths include a restriction such as orifice326, the pump discharge pressure of the fluid can be artificially increased. By artificially increasing the pump discharge pressure of the fluid over that of the actual pump discharge pressure, the pulsation dampener312can be triggered earlier as the artificially increasing pump discharge pressure exceeds the precharge pressure earlier. By engaging the pulsation dampener312earlier, pressure pulsations from the pump can be reduced earlier, even when the pump310is not functioning within the intended PSI. Eventually, the multiple flow paths return to a single pipeline302E, where the flow outputs and continues through additional components necessary in a drilling operation (not shown inFIG. 3A).

AlthoughFIG. 3Adepicts two pipelines302C and302D, any number of pipelines may be used. For example, instead of two flow paths (such as, pipelines302C and302D) branching of the pipeline302B via wye pipe303into three of more branches can be utilized. It should also be understood that the volume capacity of the two pipelines302C and302D may be different. In addition, it should also be understood that the two pipelines302C and302D may be made of different sizes, shapes, and materials. In certain embodiments, pipelines302B,302C,302D, and302E are the same size, shape, and material.

Pipeline302C, referred to as a first flow path, includes valves320and322and a restriction device such as orifice326. Pipeline302D, referred to as a second flow path includes valve324. In certain embodiments, pipeline302C includes only one valve, either valve320or valve322. It should also be understood that pump dampener system300illustrates both valves320and322to isolate orifice326. Valves320,322, and324are of conventional design and typically spring biased to their respective closed positions. Valves320,322, and324can include a variety of valve types including, but not limited to, a ball valve, a butterfly valve, a chock valve, a gate valve, and the like. Valves320,322, and324may preferably have a seal member (not shown) formed thereon to provide fluid sealing when the valves are in their respective closed and seat engaging positions. Pipeline302C is individually controlled by valves320and322. Pipeline302D is individually controlled by valve324. While pump310is operating at lower pumping pressure (such as in the initial startup phase), both pipelines302C and302D are not closed via valve320,322, or324at the same time.

Orifice326represents an orifice that restricts the flow of the fluid moving through pipeline302C.FIG. 3Billustrates an example cross section of pipe restriction similar to orifice326. In certain embodiments, the orifice326is an orifice plate that reduces pressure and restricts flow downstream. Since there is a direct correlation between the pressure, volume and the velocity of a fluid moving through a pipe, the orifice326interrupts the standard flow of the fluid. For example, when velocity of a fluid increase, the pressure increases. In contrast, when the pressure increases, the velocity increases. That is, when the flow increases or decreases the pressure will proportionally increase or decrease when the pump is a positive displacement pump. For example, when fluid passes through orifice326, the pressure decreases and the velocity increases downstream of the orifice326. Similarly, upstream of the orifice326, the pressure increases and the velocity decreases as compared to downstream conditions. Increasing the pressure upstream of the orifice326artificially raises the pump discharge pressure. Thereby the pump310is pumping against a higher pressure than the pump310is otherwise generating. Increasing the upstream pressure allows the pulsation dampener312to engage and reduce pulsations earlier. By varying the size of the orifice326, different back pressures can be attained. Specifically, varying the size of the hole in orifice326can vary the flow and thereby increase the back pressure by varying degrees.

Pipeline302C is referred to as the first flow path, as the flow initially is directed through first through pipeline302C. For example, while the pump310is ramping-up, in order to increase the pressure at the pulsation dampener312beyond the pressure as generated by the pump310a restriction, such as orifice326is utilized to increase the pressure upstream. Pipeline302D is referred to as the second flow path, as the flow is directed through pipeline302D, only after a predetermined downstream system pressure of the fluid is obtained. For example, when the pump310is ramped up to generate a pump discharge pressure capable of engaging the pulsation dampener, and the downstream system pressure is sufficient to engage precharge pressure in the discharge dampener, the artificially increased pressure via the orifice in pipeline302C (to engage the pulsation dampener312earlier in the pump310ramp-up) is not necessary. The first flow path (via pipeline302C) containing the orifice326can be essentially removed from the pump dampener system300by closing one or both valve(s)320or322. It is noted that valve324is opened prior to closing valve320or322or both. By preventing fluid from flowing through the orifice326, the pressure of the fluid is reduced to that of the pressure generated by the downstream system. By utilizing two flow paths where one flow path includes a restriction, the pressure of the fluid can be increased quicker than the pressure as generated by the pump310alone.

In certain embodiments, pump310is a positive displacement pump that displaces a constant fixed volume of fluid regardless of the pressure or velocity. For example, if the pump310is a positive displacement pump even though orifice326restricts the flow downstream of pump310, the same volume is displaced through the orifice326over the same period of time. By utilizing an orifice326, the pressure can significantly increase upstream of the orifice326. The increased pressure allows the pulsation dampener312to be engaged earlier, as the pressure of the fluid is higher than the precharged pressure of the pulsation dampener312. In certain embodiments, the precharge pressure of the pulsation dampener312is preset higher to better reduce pulsations when pump310is functioning at the system pressure, as the system pressure can be artificially achieved earlier. The pulsation dampener312is engaged earlier during the ramp-up and ramp-down of pump310, and the system spends less time under low pressures. As a non-limiting example, by increasing the precharge pressure from 1,000 psi to a higher pressure such as 2,000 psi, essentially reduces pulsation magnitudes by 50%.

In certain embodiments, when pump310is ramping-up at the start of a drilling operation, shutting down upon completion of a drilling operation, or any other non-intended pressure drop situation, valve324on pipeline302D is closed, and valves320and322on pipeline302C are open. When the flow leaves the pulsation dampener312, via pipeline302B, the flow is directed to pipeline302C. The flow is directed to pass through orifice326. Upstream of orifice326(pump310and pulsation dampener312) the pressure is increased. In contrast, downstream of orifice326(pipeline302E) the pressure is decreased and the velocity of the flow increases. For example, when the pump310is ramping up, the pump is continually increasing the pressure of the fluid and the volume moving through the pipeline302B. As the flow passes through orifice326, the pressure upstream of orifice326is artificially increased, above downstream pressure. The artificial increase in pressure is not the true pressure of the drilling operation, as it is the pressure generated by the pump and the pressure created by the orifice326. Immediately downstream of the orifice326the pressure is less than the downstream pressure as the velocity of the fluid increases as it passes through the orifice326. The pump discharge pressure can be acquired via the pump310itself and the downstream system pressure is acquired, by a sensor316or other device supplied by user, a distance downstream from the orifice326when the flow returns to its system pressure as generated by the pump310. The system pressure is measured by sensor316to determine the pressure of the fluid to be discharge downstream. The system pressure can be used to determine when to close the valve320on the pipeline302C and open the valve324on pipeline302D.

When then pump discharge pressure is above the precharge pressure of the pulsation dampener312, the valve324is open on pipeline302D. The flow is then directed to either pipeline302C or pipeline302D from pipeline302B. The pressure of the system returns to the pump discharge pressure, as the flow can bypass the orifice326in pipeline302C by traversing pipeline302D. Thereafter, the valve320, the valve322, or both, is closed to direct the flow only through pipeline302D. The flow is then directed from the pulsation dampener312through pipelines302B and302D and the flow is outputted to the remainder of the drilling system (not shown inFIG. 3A) through pipeline302E.

In certain embodiments, multiple flow paths are possible, where each flow path but one includes a restriction of varying amounts to incrementally increase and decrease the upstream pressure. For example, each pipeline can have a set of valves and an orifice of varying diameter size, in order to control the pressure during ramp up or during instances when the operating pressure is less than the pressure that is needed by the pulsation dampener312to effectively reduce pulsations. For example, the flow may be split into three or more flow paths, with each path with an increasing (or decreasing) orifice diameter size and one pipeline with no restricting orifice. This allows the transition from a restricted pipe to a free flowing pipe, and a pressure drop associated with the transition to be reduced as the system can transition through multiple restricted pipes (each with a different restriction), and maintain the downstream system pressure within a range to engage the pulsation dampener312. Each valve(s) associated with a pipe that includes a restriction can open and close to direct the fluid to flow into pipe or prevent the fluid from flowing into the pipe. This allows more control of the pressure to be obtained to maintain a pressure level above a threshold to keep the pulsation dampener312engaged.

In certain embodiments, valves320,322, and324can be manual valves or controlled automatically by a drilling system to maintain a pump discharge pressure from the pump through the downstream system. For example, the system monitors the pressure within the pipelines at various intervals, such as at pipeline302A (downstream of pump310as the flow enters pulsation dampener312) the pressure at pipeline302B (downstream of pulsation dampener312), and at pipeline302E, to identify when the back pressure created by the orifice326(the pump discharge pressure that is upstream of the orifice) is no longer necessary to engage the pulsation dampener312. That is, when the pump310generates enough pressure to engage the pulsation dampener312without the need of the back pressure created by the orifice326, the flow can be unrestricted. Thereafter, the system can open the valve324on pipeline302D to allow the flow to pass through both pipelines302C and302D. Then the system can close one or both valves320and322, essentially removing the orifice326from the system, thereby eliminating the back pressure created by the orifice326.

In certain embodiments, the orifice326is a restriction device that acts as a pressure increasing apparatus, such as a pressure regulating valve. A pressure regulating valve is a valve that reduces input to a specified output pressure. The pressure increasing unit can have a preset pressure or can be dynamically controlled to increase or decrease the back pressure as needed to engage the pulsation dampener312.

In certain embodiments, the orifice326can be a variable diameter orifice. A variable diameter orifice can regulate the back pressure without the need for three or more flow paths each with a different sized orifice to incrementally increase or decrease the back pressure.

FIG. 3Billustrates a cross sectional view301of a combination pipeline302C with a restriction (similar to orifice326ofFIG. 3A) according to various embodiments of the present disclosure. Cross sectional view301is an enlarged view of orifice326ofFIG. 3A.FIG. 3Bdoes not limit the scope of this disclosure to any particular embodiments of a precharge manifold system.

The cross sectional view301illustrates pipeline302C with a diameter355and the direction of flow illustrated by arrow352. Cross sectional view301includes orifice326, pressure sensor370, and pressure sensor375.

Orifice326is an orifice plate that is typically used to measure the rate of flow of a fluid through the plate by placing pressure sensors directly upstream and downstream of the orifice plate. The flow rate through the orifice plate can be derived based on comparing the two diameters that of the pipeline diameter355and the orifice diameter365.

The pipeline302C has a center line depicted by dashed line350. Orifice326has an opening that is sized according to the diameter365. By comparing the pressure via pressure sensor370(upstream of the orifice326) and the pressure sensor375(downstream of the orifice326) along with the ratio of the diameter355of the pipeline302C with the diameter365of the orifice326the flow rate can be derived for the fluid flowing through the pipeline302C. Similarly, based on the ratio of the diameter355of the pipeline302C with the diameter365of the orifice326the back pressure can be derived as the pump310ramps-up. For example, if pump310(ofFIG. 3A) is a positive displacement pump that displaces an average volume of fluid regardless of the pressure or velocity, and the diameters355and365are fixed, as the pump310ramps-up the pressure increases to engage the pulsation dampener312, earlier. In certain embodiments, the pressure sensors370and375can be located further upstream and downstream respectively from the orifice326. In certain embodiments, additional pressure sensors can be located through300ofFIG. 3A.

FIG. 4illustrates a flowchart of a fluid delivery and pulsation dampening system400of the pump dampener system300with multiple flow paths, according to various embodiments of the present disclosure.FIG. 4does not limit the scope of this disclosure to any particular embodiments of a precharge manifold system.

In operation402, the piping with the restriction is opened via valve320,322, or both, while the piping without the restriction (such as a free flowing pipe) is closed. Prior to engaging the pump (similar to pump310FIG. 3A) to commence ramping-up to the pump discharge pressure, the fluid is pre-directed to flow from the pump to the pulsation dampener (similar to the pulsation dampener312ofFIG. 3A) to the pipeline with the restriction. For example, the fluid is pre-directed to flow from the pump310to pipeline302C (ofFIG. 3A) via wye pipe303(ofFIG. 3A), in order for the back pressure to be increased via the orifice326(ofFIG. 3A).

A controller380can monitor the sensors315and316, receive operation information, and control valves320,322and3234. “Receive” can mean that receiving from a memory, receiving inputs from a user, etc. The operation information can include a pressure threshold, precharge pressure of the pulsation dampener, etc. The pressure threshold can be a determination of addition of the precharge pressure and the pressure drop in the restricted flow path. For example, when the pressure drop is 2500 psi and the precharge pressure 3000 psi, the pressure threshold would be 5500 psi. The controller380can use the pressure threshold in determining when to switch from the restricted flow path to the open flow path.

In operation404, the pump (similar to pump310ofFIG. 3A) is activated to start the drilling operation, thereby pumping fluid through the pipeline with the restriction (such as pipeline302C with orifice326ofFIG. 3). As the pump is ramping-up, the restriction increases the pressure upstream, where the pulsation dampener is located. By the pressure increasing quicker than the pressure that is naturally generated by the system, the pulsation dampener can be engaged earlier in the drilling operation. While the pump is active, the fluid leaves the pipeline302C and merges into the pipeline302E and continues through the rest of the system at the downstream system pressure as generated by the pump.

The controller380can determine that the pump pressure is below the operating pressure or the precharge pressure of the pulsation dampener. The controller380can close the valve on the open flow path and open the valve or valves on the restricted flow path.

In operation406, the pressure is monitored at a pulsation dampener as well as down stream of the orifice. In certain embodiments, the pressure is monitored at the pulsation dampener, upstream of the restriction, or downstream of the restriction or a combination thereof. The pressure is monitored at or near the pulsation dampener to allow an operator or the system to derive when the pulsation dampener is engaged based on the pump discharge pressure of the fluid and the precharge pressure of the pulsation dampener.

The controller380can determine that the pump pressure has reached a pressure threshold. The pressure threshold is a pressure measurement for indicating when the pump pressure is sufficient to switch from the restricted flow path to the open flow path. The pressure threshold is determined using a combination of the precharge pressure of the pulsation device and a pressure drop of the restricted flow path. The controller380can also determine that the system pressure after the discharge piping has reached an operating pressure or the precharge pressure of the pulsation dampener.

In operation408, when the desired pump discharge pressure is reached, the pipe without the restriction is opened via a valve, thereby allowing the fluid to flow through both the piping with the restriction and the piping without the restriction. For example, the fluid can flow through both pipeline302C and302D ofFIG. 3. In certain embodiments, both pipelines are opened via valves that are controlled by a control system that monitors the pressure to ensure the pulsation dampener is operating effectively. In certain embodiments, both pipelines are opened for a short period of time to prevent a large pressure drop that would cause the pulsation dampener to become ineffective at dampening pulsations caused by the pump. The fluid leaves the pipeline302C and302D and merges together into pipeline302E where the fluid continues through the rest of the system at the pump discharge pressure. The pump discharge pressure and the downstream system pressure are similar.

In operation410, the piping with the restriction is closed via at least one valve. For example, by closing valve320or322or both, the flow is directed only through pipeline302D from pipeline302B. The fluid leaves the pipeline302D and merges into the pipeline302E and continues through the rest of the system at the pump discharge pressure.

Once controller380has determined that the pump pressure has reached the pressure threshold or that the system pressure has reached the operating pressure, the controller380can open the valve on the unrestricted flow path and close the valve or valve on the restricted flow path.

AlthoughFIG. 4illustrates one example of a pulsation dampening system400, various changes may be made toFIG. 4. For example, while shown as a series of steps, various steps inFIG. 5could overlap, occur in parallel, or occur any number of times.

FIG. 5illustrates a flowchart of a fluid delivery and pulsation dampening system500of the pump dampener system300with multiple flow paths, according to various embodiments of the present disclosure.FIG. 5does not limit the scope of this disclosure to any particular embodiments of a precharge manifold system.

In operation502, the pump dampener system300, ofFIG. 3Areceives a fluid from a pump. The fluid can be used in drilling operations. The pump can be a positive displacement pump, such that the volume of fluid moved by the pump does not change, unless the pump revolutions per minute (RPM) change or the piston diameter changes. For example, when the pump is ramping up, the RPM of the pump is changes as the pump starts from a stationary position to a RPM that is used under general operating conditions.

In operation504, a pulsation dampener can be located downstream of the pump and dampens any pulsations generated by the pump. The pulsation dampener can be sized based on the general operating conditions of the system. While the pump is ramping up, the pulsation dampener may not effectively reduce pulsations as compared to the general operating conditions of the system.

In operation506, a pressure sensor can detect the pump pressure of the fluid. In operation508, the fluid can be split into two or more paths. When the fluid is split into two paths, one path is unrestricted while the other path includes a restriction. The restriction can artificially increase the pressure of the fluid to engage the pulsation dampener earlier. When the fluid is split into three or more paths, one path is unrestricted, while every other path includes a restriction to artificially increase the pressure of the fluid, to different pressures to engage the pulsation dampener earlier.

AlthoughFIG. 5illustrates one example of a pulsation dampening system500, various changes may be made toFIG. 5. For example, while shown as a series of steps, various steps inFIG. 5could overlap, occur in parallel, or occur any number of times.