Microwave Solids Mass Flow Rate Measurement in Drilling
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Solution Overview
Problem
Current methods for estimating subsurface parameters from drilling operations, such as rock and debris carried by drilling fluid to the surface, lack efficiency and accuracy in providing real-time data for controlling drilling operations and optimizing wellbore stability.
Innovation Solution
A method and apparatus that utilize a microwave field to estimate the mass flow rate of solids by separating drilling fluid from solids using a shaker, conveying the solids to a vertically aligned chute where they reach a constant velocity, and using a sensor assembly to generate signals for a control unit to calculate the mass flow rate, which is then used to provide insights into drilling efficiency and wellbore stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional methods are used to estimate subsurface parameters from drilling operations, then the process is simpler, but the accuracy and efficiency of real-time data provision is insufficient
Solution Approach 1:
The system segments the solids measurement process into distinct stages: separation of solids from drilling fluid using a shaker, conveyance through a vertically aligned chute, and microwave field interaction for mass flow rate estimation. This segmentation allows each component to be optimized independently while maintaining overall system accuracy.
Solution Approach 2:
A vertically aligned chute is introduced as an intermediary component between the shaker and the microwave sensor assembly. The chute ensures solids reach a constant velocity before entering the measurement zone, providing consistent measurement conditions and improving accuracy without significantly increasing system complexity.
2Measurement precision
If solids are measured while moving at variable velocity, then the measurement process is simpler, but the accuracy of mass flow rate estimation deteriorates
Solution Approach 1:
The vertically aligned chute is positioned above the microwave sensor assembly to allow solids to accelerate under gravity and reach a constant terminal velocity before entering the measurement zone. This preliminary action ensures that velocity variations are eliminated before measurement, improving accuracy without requiring complex velocity control mechanisms during the measurement process itself.
3Productivity
If real-time solids measurement is implemented, then drilling operation optimization is improved, but the equipment complexity and cost increase
Solution Approach 1:
The system replaces complex mechanical measurement devices with a microwave field-based measurement approach. The microwave sensor assembly non-contactly measures solids mass flow rate by detecting changes in electromagnetic field properties as solids pass through, eliminating the need for mechanical sensors that would require direct contact with moving solids and reduce reliability.
Solution Approach 2:
The microwave field measurement system is designed to operate autonomously, continuously providing real-time solids mass flow rate data without requiring manual intervention or calibration. The system self-regulates by maintaining a constant measurement zone and automatically compensating for variations in solids flow characteristics.
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
Enables accurate estimation of solid mass flow rates, aiding in optimizing drilling operations by identifying operational issues and improving hole cleaning efficiency and wellbore stability, thereby reducing unnecessary rig operations and enhancing drilling parameter control.
Implementation Method 1
a sensor assembly generating a microwave field in a section of the chute where the dropped solids have the constant velocity
Data Source
AI summary
A method for estimating a parameter relating to solids recovered from a wellbore includes drilling a wellbore using a bottomhole assembly; conveying solids in the wellbore to the surface using drilling fluid; separating the drilling fluid from the solids; and continuously dropping the solids into a solids evaluator positioned above a dryer. The solids evaluator includes a chute having a vertically aligned bore in which the dropped solids reach a constant velocity, a sensor assembly generating a microwave field, and a control unit. The control unit estimates a mass flow rate of the solids based on the generated signals. The method may further include generating the signals representative of a mass flow rate of the dropped solids using the sensor assembly and using the control unit to estimate the mass flow rate of the solids based on the generated signals.