Drilling Mud Flow Monitoring for Uninterrupted Circulation Pressure Control
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Solution Overview
Problem
Existing mud circulation systems in drilling rigs experience interruptions and pressure variations when adding or removing drill pipes, leading to potential well instability and safety risks due to the reliance on Coriolis principle-based flow measurement systems that are prone to clogging and maintenance issues.
Innovation Solution
A control equipment with measuring devices, including Venturi tubes and sensors, is integrated into the mud circulation circuit to continuously monitor and control mud flow, ensuring uninterrupted circulation and maintaining constant pressure at the well bottom, eliminating the need for annulus pressurization and reducing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If Coriolis principle-based flow measurement systems are used to monitor mud flow, then flow measurement capability is provided, but the system is prone to clogging and maintenance issues
Solution Approach 1:
The patent extracts the flow measurement function from the problematic Coriolis principle-based system and implements it using separate, simpler measurement devices including a flow meter and pressure sensors positioned at strategic locations in the mud circulation circuit. This separates the measurement function from the mud flow path, eliminating clogging issues while maintaining measurement capability.
Solution Approach 2:
The patent introduces intermediary measurement devices (flow meter, pressure sensors) that indirectly measure mud flow parameters without being directly exposed to the mud flow in a way that causes clogging. These intermediaries provide the necessary measurement data through pressure differentials and flow rate calculations rather than direct Coriolis measurement.
2Adaptability or versatility
If pump is stopped to add a stand of drill pipes, then drill pipe addition is enabled, but mud circulation is interrupted causing well instability
Solution Approach 1:
The patent implements a bypass circuit that allows mud circulation to continue uninterrupted through the well annulus even when the main pump is stopped for drill pipe addition. The bypass maintains continuous mud flow and pressure in the wellbore, preventing well instability while enabling the operational need to add drill pipes.
Solution Approach 2:
The patent segments the mud circulation system into main circulation path and bypass path, allowing independent operation of each. This segmentation enables the bypass to carry mud flow continuously while the main pump can be stopped for drill pipe operations, resolving the contradiction between operational flexibility and well stability.
3Stress or pressure
If annulus pressurization is used to maintain pressure during pipe addition, then pressure control is achieved, but system complexity increases
Solution Approach 1:
The patent enables the bypass circuit to self-regulate pressure through its inherent flow characteristics and the natural pressure differential created by continuous mud circulation. The system maintains pressure control automatically without requiring complex active pressurization equipment, achieving pressure stability through the passive flow dynamics of the bypass arrangement.
4Reliability
If multiple protection barriers are implemented, then safety is improved, but device complexity increases
Solution Approach 1:
The patent designs the bypass circuit and monitoring system to serve multiple protective functions simultaneously: maintaining well pressure, enabling drill pipe operations, and providing continuous flow monitoring. This multi-functionality achieves enhanced safety through multiple protection barriers while avoiding the complexity increase that would result from separate dedicated systems for each function.
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 solution enables continuous, safe, and efficient mud circulation, maintaining a stable hydraulic barrier during all drilling phases, reducing maintenance costs and operational risks, and ensuring reliable protection against well instability and leaks.
Implementation Method 1
A control equipment with measuring devices, including Venturi tubes and sensors, is integrated into the mud circulation circuit to continuously monitor and control mud flow
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
Control equipment (3) for monitoring flows (F) of drilling mud in a drilling mud circulation circuit (2). The equipment comprises: at least one first inlet element (32), in turn comprising at least one first measuring device (4); at least one second outlet element (34), in turn comprising at least one second measuring device (5), and a processing and control unit (38) electrically connected to both the first measuring device (4) and the second measuring device (5). The processing and control unit (38) receives measurement data from said first measuring device (4) and said second measuring device (5). Said equipment comprises a third control element (36), in turn comprising at least one third measuring device (6). The processing and control unit (38) is electrically connected to said at least one third measuring device (6); it receives measurement data from said third measuring device (6), and processes the data thus obtained by means of a model-based mathematical algorithm. The equipment (3) comprises a signaling device (7), which is electrically connected to said processing and control unit (38).