Drill String Calibration Tool for Consistent Rig Sensor Accuracy
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Solution Overview
Problem
Existing well drilling systems face inaccuracies in rig sensors due to varying sensor types, locations, and skill levels, leading to inconsistent operational parameter information, which can result in inefficiencies and increased costs.
Innovation Solution
A sensor calibration tool attached to the drill string measures operational parameters and compares them with rig sensors, using a data gathering and analysis module to calibrate and adjust sensors, ensuring accurate data transmission and display.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If rig sensors are used to measure operational parameters, then data can be collected for monitoring drilling operations, but measurement precision deteriorates due to varying sensor types, locations, and calibration levels
Solution Approach 1:
A calibration tool is introduced as an intermediary device that attaches to the drill string and provides a known reference mass. This calibration tool serves as a mediator between the drill string and the rig sensors, enabling standardized calibration measurements regardless of sensor type or location. The tool includes attachment mechanisms (clamps or threaded connections) that adapt to different drill string configurations while maintaining consistent calibration functionality.
Solution Approach 2:
The system changes the operational parameters of the rig sensors by introducing known mass values through the calibration tool. By attaching the calibration tool with known mass to the drill string and measuring the change in hook load sensor readings, the system establishes reference points for calibrating the sensors. This parameter-based calibration approach standardizes measurements across different sensor types and locations.
2Productivity
If multiple different rig sensors are deployed across various surface components, then comprehensive operational data can be collected, but device complexity increases making calibration and maintenance difficult
Solution Approach 1:
The calibration tool is designed as a universal device that can be attached to drill strings of various sizes and configurations using different attachment mechanisms (clamps for smaller drill strings, threaded connections for larger ones). This multi-functional design allows a single calibration tool to work across different rig configurations and sensor types, simplifying the calibration process despite system complexity.
Solution Approach 2:
The system performs preliminary calibration actions by attaching the calibration tool to the drill string before drilling operations begin. This preliminary calibration establishes baseline measurements and sensor accuracy, allowing operators to identify and correct calibration issues before they affect drilling operations. The calibration process is performed in advance to prevent measurement errors during actual drilling.
3Measurement precision
If sensor calibration is performed frequently to maintain accuracy, then measurement precision is improved, but loss of time occurs during calibration procedures
Solution Approach 1:
The calibration tool enables preliminary calibration to be performed quickly by attaching a known mass to the drill string and recording sensor readings. This preliminary calibration can be done rapidly at the beginning of drilling operations or when drilling conditions change, providing timely accuracy checks without requiring extensive calibration procedures. The known mass reference allows for quick comparison and adjustment of sensor readings.
Solution Approach 2:
The calibration tool provides self-service calibration capabilities by incorporating known reference masses and providing clear calibration procedures. Operators can perform calibration independently without requiring specialized equipment or extensive training, reducing the time and resources needed for calibration. The tool itself serves as the calibration standard, eliminating the need for external calibration equipment.
Data Source
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Figure 2
Figure 3~4A
AI summary
A method includes attaching a sensor calibration tool to a drill string. The sensor calibration tool includes a first tool sensor configured to measure a first operational parameter. A first tool sensor measurement of the first operational parameter is received from the first tool sensor, where the drill string is disposed at least partially within a wellbore and supported by a surface rig system and the sensor calibration tool is positioned on the drill string at a surface location proximate to the surface rig system. A first rig sensor measurement of the first operational parameter is received from a first rig sensor positioned on a first surface component of the surface rig system. The first rig sensor is calibrated based on a comparison of the first tool sensor measurement with the first rig sensor measurement.