Closed-Loop Kick Detection in Drilling Systems
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Solution Overview
Problem
Current kick detection methods in drilling operations are unreliable due to assumptions of steady-state flow and pressure changes, leading to false detections and inadequate detection of various kick types, which can result in operational delays and safety hazards.
Innovation Solution
A controlled pressure drilling method that monitors flow-in, flow-out, density, and standpipe pressure to identify specific events such as gas-at-surface, kick, high-pressure low-volume depletion, and gas expansion, using real-time data and automated choke control to manage wellbore pressure and prevent fluid influx or loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional kick detection methods are used that assume steady-state flow and pressure changes, then the detection process is simple, but the reliability of kick detection deteriorates leading to false detections and inadequate detection of various kick types
Solution Approach 1:
The patent applies dynamics by transitioning from steady-state assumptions to dynamic modeling that captures transient behavior. The system uses dynamic equations to model wellbore pressure, flow rates, and fluid properties during kick events, allowing detection of various kick types (gas, liquid, mixed) by analyzing transient responses rather than assuming equilibrium conditions.
Solution Approach 2:
The patent changes parameters by introducing multiple measurable variables including flow-in rate, flow-out rate, wellbore pressure, fluid density, and temperature. These parameter changes enable the system to distinguish between different kick types by analyzing how each parameter evolves over time, improving detection reliability beyond simple pressure or flow monitoring.
2Speed
If data collection frequency is increased to properly detect kicks, then the detection speed improves, but the use of energy and data processing requirements increase
Solution Approach 1:
The patent implements feedback by continuously monitoring multiple parameters and using dynamic models to predict expected values. The system compares actual measurements with model predictions, and only triggers alerts when deviations exceed thresholds, enabling fast detection without requiring maximum data collection frequency at all times.
Solution Approach 2:
The patent applies preliminary action by pre-calculating dynamic response models for different kick scenarios during system initialization. These pre-computed models allow the real-time detection system to quickly compare actual data against expected behavior without performing complex calculations during high-frequency data collection, reducing energy consumption while maintaining detection speed.
3Difficulty of detecting and measuring
If return flow measurements are used to detect kicks, then the detection capability improves, but measurement precision deteriorates due to heave effects, mud transfers, and imprecision in tank level measurements
Solution Approach 1:
The patent applies universality by using multiple measurement methods simultaneously - flow-in rate measurement at the pump, wellbore pressure monitoring, fluid density measurement, and return flow monitoring. This multi-functional approach allows the system to cross-validate measurements and compensate for imprecision in any single measurement method, improving overall detection capability while mitigating individual measurement errors.
Solution Approach 2:
The patent uses dynamic modeling as an intermediary that reconciles imprecise return flow measurements with other more accurate measurements. The model integrates data from multiple sources and accounts for heave effects and mud transfers, producing a more accurate estimate of actual kick conditions than any single measurement could provide alone.
Data Source
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Figure 3A~3B
AI summary
Controlled pressure drilling of a borehole with a drilling system detects events and identifies the events as being one of a gas-at-surface event, a kick event, a high-pressure low-volume depletion event, and a gas expansion event. Parameters including flow-in, flow-out, density, and standpipe pressure are monitored. A volume increase is detected between the flow-in and flow-out, and an initiation point of the detected volume increase is identified. At this point, an event from the initiation point is identified based on the monitored parameters from the initiation point. To identify a kick event, for example, the standpipe pressure is determined to have increased from the initiation point without the density decreasing since the initiation point, and a cumulative volume value from the initiation point is determined to be above a first threshold. In response to the identified event, an action is initiated in the drilling system.