Automated Well Control System for Influx Detection
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Solution Overview
Problem
Conventional well control methods in open-to-atmosphere systems are inadequate for accurately and quickly detecting self-sustained fluid influxes, leading to delays, increased risk of fracture, and operational inefficiencies due to reliance on manual flow checks that can be affected by installation motion and heave effects.
Innovation Solution
An automated system that initiates an initial well control protocol based on preselected criteria, specifically fluid flow rate or volumetric rate, without manual intervention, using a controller to interface with well control systems and automatically adjust operations such as raising the drill string, stopping mud pumps, and closing the blowout preventer, thereby reducing the risk of influx and minimizing delays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional manual flow check procedures are used in open-to-atmosphere systems, then operational simplicity is maintained, but detection accuracy and response speed deteriorate due to installation motion and heave effects
Solution Approach 1:
The patent replaces manual mechanical flow check procedures with an automated electronic detection system that uses sensors and a controller to monitor fluid flow rate and volumetric rate. This substitution eliminates the impact of installation motion and heave effects on detection accuracy while maintaining ease of operation through automatic monitoring and alerting.
2Reliability
If manual flow check procedures are performed to confirm influx, then operational caution is exercised, but response time deteriorates due to prescribed minimum waiting periods
Solution Approach 1:
The automated system performs continuous preliminary monitoring of fluid flow rate and volumetric rate, maintaining readiness to detect influx conditions without requiring prescribed waiting periods. The system can immediately identify and respond to influx events, eliminating the time loss associated with manual flow check procedures while maintaining operational caution through controlled response protocols.
3Speed
If automated detection based on fluid flow rate is implemented, then response speed improves, but system complexity increases
Solution Approach 1:
The controller is designed to perform multiple functions: monitoring fluid flow rate, monitoring volumetric rate, comparing readings to threshold values, generating alerts, and initiating well control operations. By consolidating these functions into a single multi-functional device, the system achieves fast response speed while minimizing the increase in overall system complexity.
4Measurement precision
If continuous automated monitoring is implemented, then detection accuracy improves, but cost increases
Solution Approach 1:
The system uses feedback by continuously comparing sensor readings of fluid flow rate and volumetric rate against pre-determined threshold values. This feedback mechanism enables accurate detection of influx conditions while allowing for adjustable sensitivity levels that can optimize the balance between detection accuracy and operational cost based on specific well conditions and risk tolerance.
Data Source
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AI summary
An automated system for use in well control comprises a controller configured to receive an input signal indicative of a fluid flow rate or fluid volumetric rate from a wellbore. The controller is configured to determine from the input signal whether the fluid flow rate or fluid volumetric rate exceeds a preselected threshold indicative of a fluid influx condition in the wellbore system. On determining that the fluid flow rate or fluid volumetric rate exceeds the preselected threshold, the controller is configured to automatically output one or more command signals initiating an initial well control protocol.