Drilling Pump Flow Estimation Using Pressure and Cycle Data
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Solution Overview
Problem
Existing flow meter technologies struggle to accurately measure the flow rate of high-pressure drilling fluid pumps due to the high-pressure constraints and properties of drilling fluids, requiring heavy modifications to the drilling rig circulation system and lacking real-time efficiency adjustments.
Innovation Solution
A method for estimating real-time flow rate of fluid pumps using a calculation model based on fluid pressure, number of cycles, and calibration parameters, such as fluid density and geometrical volumes, with a calibration procedure to determine constant coefficients, allowing for real-time flow rate estimation and detection of kicks or losses in the wellbore.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If flow meters are used to measure the flow rate of high-pressure drilling fluid pumps, then measurement accuracy is improved, but device complexity and system modification requirements increase significantly
Solution Approach 1:
The patent replaces mechanical flow meters with a calculation-based estimation system that uses pump operational parameters (pressure, cycles, efficiency) to determine flow rate. This substitution eliminates the need for physical flow measurement devices and their associated system modifications while maintaining measurement capability through computational methods
Solution Approach 2:
The patent introduces a calculation model as an intermediary between pump operational parameters and flow rate determination. This model uses measurable parameters like pressure and cycle count to indirectly estimate flow rate, avoiding direct flow measurement and its associated complexity
2Productivity
If constant efficiency is assumed for pump calculations, then calculation simplicity is maintained, but flow rate estimation accuracy deteriorates due to variable real-world efficiency
Solution Approach 1:
The patent transitions from static constant efficiency assumptions to dynamic efficiency determination. The system calculates pump efficiency in real-time based on operational parameters and uses this variable efficiency value in the flow rate calculation model, allowing the system to adapt to changing pump conditions while maintaining calculation speed through efficient algorithms
3Measurement precision
If calibration procedures are implemented to determine model coefficients, then estimation accuracy is improved, but time and operational requirements increase
Solution Approach 1:
The patent performs calibration procedures during periods when the well is already being operated (cased hole operations), utilizing existing operational data rather than requiring separate dedicated calibration time. This approach integrates calibration into normal operations, minimizing additional time requirements while still achieving accurate model parameter determination
Data Source
AI summary
The disclosure relates to a method for estimating a flow out of at least one fluid pump for injecting fluid in a well, comprising: —determining a calculation model for the flow rate of a pump exiting the at least one pump, said calculation model permitting the calculation of the flow rate in function of at least one calculation parameter (p, SPAM) related to the at least one fluid pump; then —providing at a plurality of measuring times (tm), a set of measurement values (PDH,m, PB,m, SPMDH,m, SPMB,m) representative of said at least one calculation parameter; then —estimating (86) the flow rate exiting the pump in function of the model and of said at least one calculation parameter.