Flow Control System for Drilling Kick Prevention
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Solution Overview
Problem
Current methods for detecting and controlling pressure changes during offshore hydrocarbon drilling are imprecise and time-consuming, leading to potential catastrophic equipment failure and safety risks due to uncontrolled influxes of formation fluids.
Innovation Solution
A flow control system comprising a conduit for the drill pipe, a sensor array to detect the flow rate of returning drilling fluid, and a flow control device with holding elements to stabilize and control the flow, actuated in response to detected events, which applies back pressure to prevent kicks without stopping drilling operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If drilling fluid level monitoring is used to detect flow changes, then operators can identify potential kicks, but the detection is imprecise and time-consuming
Solution Approach 1:
The patent replaces the mechanical/visual monitoring method (drilling fluid level monitoring) with an electronic sensor array system that uses electrical or electronic signals to detect flow changes. This substitution enables precise, real-time detection of flow rate changes, directly improving measurement precision and eliminating the time delay associated with manual or visual monitoring methods.
2Reliability
If operators shut the well in with rams or annulars to increase hydrostatic pressure, then kicks can be controlled, but drilling operations must be stopped for about half a day
Solution Approach 1:
The patent implements preliminary action by positioning a flow control device in advance within the annular space between the drill string and riser. When a kick is detected by the sensor array, the pre-positioned flow control device can be activated immediately to apply back pressure and control the influx, eliminating the need to shut in the well with rams or annulars and allowing drilling operations to continue without interruption.
Solution Approach 2:
The patent introduces a flow control device as an intermediary element in the annular space between the drill string and riser. This intermediary device provides a controlled method to manage kick conditions by regulating fluid flow in the annular space, offering a less disruptive alternative to shutting in the well with blowout preventers while maintaining kick prevention capability.
3Reliability
If formation fluid pressure exceeds drilling fluid pressure, then influxes occur, but current monitoring systems cannot detect and respond quickly enough
Solution Approach 1:
The patent implements a feedback mechanism where the sensor array continuously monitors flow rate changes in real-time and provides immediate information about pressure imbalances and potential kicks. This continuous feedback loop enables operators to detect when formation fluid pressure exceeds drilling fluid pressure and respond promptly, improving both the reliability of influx detection and the speed of response compared to traditional monitoring systems.
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 system enables rapid and precise detection and control of returning drilling fluid flow, preventing kicks and blowouts by increasing hydrostatic pressure, thus enhancing drilling safety and productivity.
Implementation Method 1
a sensor array configured to detect a flow rate of the returning drilling fluid
Implementation Method 2
The drilling fluid maintains a hydrostatic pressure to counter-balance the pressure of fluids coming from the well
Implementation Method 3
a flow control device...configured to control the flow rate of the returning drilling fluid...actuated in response to the event detected by the sensor array
Data Source
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AI summary
A flow control system for drilling a well comprises a conduit defining a channel configured to accommodate a drill pipe and a flow of a returning drilling fluid, and an acoustic sensor array configured to detect a flow rate of the returning drilling fluid. The flow control system further comprises a flow control device configured to control the flow rate of the returning drilling fluid and to be actuated in response to an event detected by the sensor array, the flow control device being proximate to the sensor array.