Drilling Mud Flow Detection via Differential Pressure and Ultrasonic Sensing
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Solution Overview
Problem
Current methods for detecting changes in wellbore flow rates during oil and gas drilling operations are inadequate for early detection, leading to potential blowouts and lost circulation, which can result in environmental hazards and safety risks.
Innovation Solution
The development of Pressure Sensing Apparatus and Flow Chamber Apparatus, equipped with multiple pressure sensors and bidirectional ultrasonic flow sensors, which monitor pressure differences and flow rates to detect fluid influx or efflux in the wellbore, providing early warnings and accurate measurements of flow rate changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional flow rate monitoring methods are used, then the system structure remains simple, but the detection timing is delayed and cannot provide early warning
Solution Approach 1:
The patent applies preliminary action by measuring the differential pressure between the upper and lower portions of the wellbore annulus to detect flow rate changes before they become significant. This early detection mechanism allows the system to identify potential kicks or lost circulation issues at their inception, providing timely warning before conventional monitoring methods would detect the problem.
Solution Approach 2:
The patent uses differential pressure measurement as an intermediary parameter to indirectly detect flow rate changes. Instead of directly measuring flow rate, the system measures the pressure difference between two points in the annulus, which serves as a sensitive indicator of flow changes. This intermediary approach enables early detection while maintaining relatively simple instrumentation.
2Measurement precision
If multiple pressure sensors are installed to improve detection accuracy, then the measurement precision improves, but the device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the wellbore annulus into upper and lower measurement zones and installing pressure sensors at each zone. This segmentation allows differential pressure measurement, which provides sensitive detection of flow rate changes. The segmented approach achieves high measurement precision while keeping the number of sensors minimal (only two pressure sensors are needed).
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
These apparatuses enable significantly earlier detection of wellbore fluid changes, enhancing safety, reducing environmental impact, and preventing blowouts by accurately determining fluid gain or loss, flow rates, and cumulative volume, thereby protecting wildlife and minimizing oil spills.
Implementation Method 1
bidirectional ultrasonic flow sensors, which monitor pressure differences and flow rates to detect fluid influx or efflux in the wellbore
Implementation Method 2
at least one pressure sensor having an upper and lower pressure sensor port positioned in a return wellbore
Data Source
AI summary
The flow of well mud being pumped by a drilling rig pump into a wellbore is sensed by monitoring at least one signal from at least one sensor of drilling mud, determining a total well drilling pump mud output rate, and determining an apparent annular mud rate based on the at least one signal and the total pump drilling rate.