Mud Pump Efficiency Detection via Transfer Pump Operating Rates

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Solution Overview

Problem

Current methods for detecting fluid influx, fluid loss, and changes in mud pump efficiency in well drilling fluid supply and circulation systems are limited by reliance on precise calibration, gravity flow, and mechanical/pneumatic separation principles, which restrict flexibility and safety in drilling rig design.

Innovation Solution

A method that utilizes existing mud circulation system devices by measuring the operating rates of transfer pumps to identify anomalous mud flow through metering tanks, allowing for detection of fluid influx, fluid loss, and pump efficiency changes without relying solely on gravity flow or mechanical/pneumatic separation, and enables flexible placement of mud treatment equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If precisely calibrated accurate devices are used to measure flow rates and volumes into and out of the wellbore, then measurement precision is improved, but device complexity and cost increase

Engineering Contradiction:

Improveflow rate measurement precisionVSAvoidmeasurement system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The system uses the existing mud pumps' own operating parameters (strokes per minute) to infer flow rates, allowing the equipment to self-report its performance without external measurement devices. The pump's operational data serves the dual purpose of driving fluid circulation and providing measurement information.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces mechanical flow measurement devices with an electronic/digital system that calculates flow rates based on pump operating parameters. Instead of using physical flow meters, the system uses computational methods to determine flow based on readily available pump performance data.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Use of energy by moving object

If gravity flow is used to move returned mud to processing equipment, then energy consumption is reduced, but placement flexibility of processing equipment is limited

Engineering Contradiction:

Improveenergy for mud transportVSAvoidequipment placement flexibility

Core Design Contradiction:

Use of energy by moving objectVSAdaptability or versatility

Solution Approach 1:

The system uses hydraulic principles by positioning processing equipment at lower elevations than the wellbore, allowing mud to flow downward under gravity. This hydraulic arrangement enables flexible equipment placement while maintaining energy-efficient gravity-driven flow, as equipment can be located anywhere along the downward slope rather than being constrained to specific gravity high points.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Ease of manufacture

If open mechanical and pneumatic separation devices are used for cuttings removal, then separation effectiveness is achieved, but safety is compromised due to exposure to combustible and toxic fumes

Engineering Contradiction:

Improveseparation device implementationVSAvoidexposure to hazardous fumes

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The system employs enclosed separation devices that contain the mud and cuttings processing within sealed chambers. These enclosed structures prevent hazardous fumes from escaping into the environment while still allowing effective mechanical and pneumatic separation of cuttings from mud, thus eliminating worker exposure risks without compromising separation performance.

Inventive Principle:

Principle #30Flexible shells and thin films

4Reliability

If additional equipment is installed to detect fluid anomalies, then detection reliability is improved, but device complexity and cost increase

Engineering Contradiction:

Improvefluid anomaly detection reliabilityVSAvoiddetection system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system uses existing mud pump equipment to serve multiple functions: both circulating drilling fluid and providing detection data for fluid anomaly identification. By analyzing operating parameters from pumps already present in the system, the invention achieves reliable anomaly detection without adding dedicated detection hardware, thus maintaining high reliability while avoiding increased complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11566480B2Method for detecting fluid influx or fluid loss in a well and detecting changes in fluid pump efficiency

Publication Date: 2023.01.31 NOBLE SERVICES CO LLC

AI summary

A method for identifying anomalous mud flow includes determining an operating rate of a mud pump discharging to a pipe string in a wellbore. Mud returned from the wellbore is moved to a first metering tank. Mud is moved from the first transfer tank to a mud storage tank using a first pump having a flow rate directly related to an operating rate thereof. A first parameter related to volume of mud in the first metering tank is measured. Anomalous mud flow is identified by detecting changes in the operating rate of the first pump wherein the operating rate is adjusted to maintain the first parameter substantially constant.