External Sensor Assembly for Drilling Fluid Flow Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Accurate and reliable measurement of drilling fluid flow rate in open channel fluid return is challenging due to difficulties in detecting fluid influx or loss, which can lead to dangerous conditions such as blowouts or reduced hydrocarbon return, as existing methods are either invasive, prone to damage, or slow and inaccurate.
Innovation Solution
A sensor assembly is detachably coupled to the exterior surface of the fluid conduit, comprising fluid flow sensors and a fluid level sensor, which measure velocity and level to calculate the flow rate using the equation Q=v*A, where Q is the flow rate, v is the velocity, and A is the cross-sectional area, without being subjected to the fluid flow, thereby avoiding damage and providing real-time data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If fluid flow sensors are placed inside the fluid conduit to measure flow rate, then measurement accuracy is improved, but the sensors are subjected to fluid flow and prone to damage
Solution Approach 1:
The patent uses the external surface of the fluid conduit as an intermediary medium. Sensors are coupled to the exterior surface to detect flow characteristics without being exposed to the fluid itself. The conduit wall transmits flow-related information (such as vibrations, pressure waves, or thermal patterns) from the fluid to the external sensors, enabling accurate measurement while protecting the sensors from direct fluid contact and potential damage.
Solution Approach 2:
The patent replaces direct mechanical contact measurement with indirect detection methods. Instead of placing sensors that physically contact the fluid flow, the system uses external sensors that detect flow characteristics through the conduit wall, substituting a potentially damaging mechanical intrusion with a non-invasive detection approach.
2Reliability
If non-invasive sensors are coupled to the exterior surface of the fluid conduit, then sensor reliability is improved by avoiding fluid contact, but measurement accuracy may be reduced
Solution Approach 1:
The fluid conduit exterior surface serves as an intermediary that transmits flow information to external sensors. The sensors detect subtle changes in the conduit wall caused by fluid flow (such as vibrations, pressure variations, or thermal patterns), allowing accurate measurement without direct fluid contact. This intermediary approach maintains both sensor reliability and measurement precision.
Solution Approach 2:
The patent transitions from one-dimensional direct flow measurement to multi-dimensional indirect detection. By placing sensors on the external surface, the system captures flow information through additional spatial dimensions (conduit wall vibrations, surface temperature distribution, external pressure patterns), compensating for the lack of direct fluid contact and maintaining measurement accuracy.
3Reliability
If traditional fluid flow detection methods are used, then fluid influx or loss can be detected, but the detection is slow and inaccurate
Solution Approach 1:
The patent implements continuous real-time monitoring of flow characteristics using external sensors on the conduit surface. By continuously measuring flow rate and comparing it to expected values, the system detects anomalies (influx or loss) as they occur, rather than relying on periodic or delayed detection methods. This preliminary continuous action enables rapid response to changing well conditions.
Solution Approach 2:
The system establishes a feedback loop where external sensors continuously measure flow rate, the control system compares measurements to expected values, and adjustments are made in real-time. This feedback mechanism enables rapid detection of fluid influx or loss conditions, providing timely alerts to operators to prevent dangerous situations while optimizing drilling operations.
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
This solution enables accurate and reliable real-time measurement of fluid flow rates, allowing for timely adjustments to hydrostatic pressure, preventing fluid influx or loss, and optimizing drilling operations by tracking flow rates over time.
Implementation Method 1
The sensor assembly includes at least one ultrasonic sensor aligned to measure a transit interval of the fluid
Implementation Method 2
calculate a flow rate of the fluid within the open channel fluid conduit based on the received measurement... Q=v*A, where Q is the flow rate, v is the velocity, and A is the cross-sectional area
Data Source
AI summary
An example method for determining fluid flow in an open channel fluid conduit may include coupling a sensor assembly to an exterior surface of the open channel fluid conduit. Measurements may be received from the sensor assembly. The method may further include calculating a flow rate of a fluid within the open channel fluid conduit based, at least in part, on the received measurement.