Floating Laser Range Finder for Annulus Mud Level Monitoring
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Solution Overview
Problem
In drilling operations, maintaining the hydrostatic pressure of the mud column in the wellbore is challenging, especially during severe mud loss or lost circulation scenarios, where the mud level in the annulus drops, leading to reduced hydrostatic pressure and making it difficult to detect influxes, which can result in catastrophic events like blowouts.
Innovation Solution
A Mud Cap Optimization System (MCOS) utilizing floating laser range finder transmitters and receivers is deployed in the annulus, allowing for continuous monitoring of the mud fluid level, enabling accurate adjustment of the pump rate and mud cap weight to maintain a stable dynamic mud fluid level, thereby preventing excessive hydrostatic pressure and detecting early signs of kicks or loss zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the drill string is pulled out of the wellbore to change drill bit or make measurements, then the drilling operation can proceed to the next stage, but the mud level in the annulus drops causing reduced hydrostatic pressure and potential influx
Solution Approach 1:
The patent applies preliminary action by pumping additional mud (mud cap) into the annulus before pulling the drill string out of the hole. This pre-filling of the annulus with mud ensures that when the drill string is removed, the hydrostatic pressure is already maintained at appropriate levels, preventing influx while allowing the drilling operation to proceed efficiently
Solution Approach 2:
The patent implements feedback by continuously monitoring the mud level in the annulus using sensors and surface indicators. This real-time monitoring provides information about mud level changes during drill string removal, allowing operators to adjust pumping rates and mud cap volume to maintain proper hydrostatic pressure and prevent wellbore instability
2Reliability
If mud is pumped into the wellbore to maintain hydrostatic pressure during severe mud loss, then the hydrostatic pressure can be maintained, but the mud level in the annulus may still drop preventing surface reading and measurement
Solution Approach 1:
The patent uses an intermediary measurement system consisting of floating devices with sensors and surface indicators that can detect mud level changes even when the mud column does not extend to the surface. These intermediaries transmit information about downhole mud levels to the surface, allowing continuous monitoring and measurement of mud properties despite severe mud loss conditions
Solution Approach 2:
The patent replaces the traditional mechanical reliance on a continuous mud column extending to the surface for measurement with an electronic sensing system. The floating devices equipped with sensors and communication systems substitute the mechanical mud column interface with an electronic information transmission system, enabling measurement without a surface-extending mud column
3Adaptability or versatility
If the mud column does not extend to the surface due to drilling technique or downhole conditions, then drilling can proceed in challenging formations, but the mud level cannot be read at the surface and mud properties cannot be measured
Solution Approach 1:
The patent employs intermediary floating measurement devices within the annulus that can operate at various depths and transmit data to the surface. These intermediaries enable mud level and property measurement in non-traditional drilling configurations where the mud column does not reach the surface, maintaining adaptability while recovering information
Solution Approach 2:
The patent creates a universal measurement system that can function in multiple drilling scenarios - whether the mud column extends to the surface or not, whether during normal drilling or drill string removal, and under various downhole conditions. The multi-functional floating devices and surface indicators provide universal mud level monitoring capability across different drilling techniques and formations
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
The MCOS ensures water conservation and reduces drilling costs by optimizing mud consumption, improves kick detection, and enhances well integrity through accurate monitoring of annulus levels, allowing for timely intervention and optimized cementing operations.
Implementation Method 1
at least one floating device floating on a top surface of a drilling fluid in the annulus
Implementation Method 2
A Mud Cap Optimization System (MCOS) utilizing floating laser range finder transmitters and receivers
Data Source
AI summary
An apparatus is used on top of a column of drilling fluid in an annulus of a wellbore. The apparatus includes at least one floating device, at least one receiver, a communication interface coupled to the at least one receiver, a processor coupled to the at least one receiver and the communication interface, and a memory coupled to the processor. The memory includes instructions configured to perform a method that includes obtaining a start command to generate fluid level data, generating the fluid level data using the at least one floating device and the at least one receiver, and transmitting the fluid level data using the communication interface.