Downhole Drilling Event Detection with Closed-Loop Flow Sensing
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Solution Overview
Problem
Conventional methods for detecting downhole drilling events, such as kicks and lost circulation, are inaccurate and prone to false alarms due to external vibrations and open system flow measurements, especially in closed-loop systems, which affect the efficiency and safety of drilling operations.
Innovation Solution
A sensor arrangement mounted inside a tubular surrounding the drill pipe, comprising sensors and a processor to process data for detecting downhole events, using a predictive model with uncertainty windows to classify and predict drilling issues, and a software element to control the detection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional flow rate meters are installed on the return flow line to measure outflow, then quick feedback on detecting lost circulation and kick events is provided, but the measurements are not accurate because the return flow line is an open channel and is not always full of fluid
Solution Approach 1:
The patent introduces an intermediary closed-loop flow line that connects the return flow line to the drill string, creating a sealed measurement environment. This closed-loop system allows accurate flow measurement while maintaining quick feedback capability, as the fluid circulates through a controlled path where meters can be properly installed and function reliably.
Solution Approach 2:
The patent changes the system configuration from an open channel flow line to a closed-loop flow system. This parameter change enables the installation of flow rate meters in a controlled environment where the flow line is always full of fluid, thereby improving measurement accuracy while maintaining the speed of feedback through continuous monitoring.
2Measurement precision
If Coriolis flowmeters are used to measure inflow and outflow accurately, then precise flow measurement is achieved, but motor- and compressor-induced vibrations interfere with the Coriolis flowmeter own vibrations which results in false readings
Solution Approach 1:
The patent extracts the flow measurement function from the conventional return flow line location and relocates it to a closed-loop flow line that is isolated from the main drilling operation vibrations. By separating the measurement system from the vibration source, the Coriolis flowmeter can operate accurately without interference from motor and compressor vibrations.
Solution Approach 2:
The closed-loop flow line acts as an intermediary that isolates the flow measurement system from the vibration sources in the main drilling operation. This intermediary structure allows the Coriolis flowmeter to function in a stable environment while still monitoring the drilling fluid flow accurately.
3Measurement precision
If flow rate meters are installed on the return flow line in closed-loop systems, then accurate outflow measurement is achieved, but the system complexity increases
Solution Approach 1:
The closed-loop flow line serves multiple functions: it provides accurate flow measurement, isolates the measurement system from vibrations, and maintains continuous fluid circulation. By integrating these functions into a single system, the patent achieves accurate outflow measurement without proportionally increasing system complexity.
Solution Approach 2:
The patent combines the flow measurement system with the existing drilling fluid circulation system by creating a closed-loop configuration that integrates the return flow line with the drill string. This merging approach allows accurate measurement while utilizing existing system components, thereby limiting the increase in overall system complexity.
Data Source
AI summary
An arrangement for detecting a downhole drilling event during a drilling operation by a drill pipe being partially surrounded by a tubular, wherein the arrangement comprises a sensors holder to be mounted inside of the tubular and to be mounted to surround part of the drill pipe, a plurality of sensors for sensing sensor data indicative of downhole drilling events, wherein at least part of the sensors is mounted on the sensors holder, and a processor configured for processing the sensor data to thereby detect a downhole drilling event.