Non-intrusive Rheometer for Well Operations

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Solution Overview

Problem

Existing technologies face challenges in real-time determination of rheological properties of fluids used in wells, particularly in managed pressure drilling, due to varying viscosity over time and non-Newtonian fluid behavior.

Innovation Solution

A rheology measurement apparatus is introduced, which includes a main flow passage and a bypass flow passage connected in parallel. This apparatus uses a mass flowmeter and variable flow restrictors to measure rheological parameters without altering the pump flow rate, enabling real-time viscosity determination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a traditional rheometer is used to measure fluid viscosity, then measurement capability is provided, but the device is intrusive and alters the pump flow rate

Engineering Contradiction:

Improveviscosity measurement capabilityVSAvoidflow rate alteration

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The system divides the flow into two separate passages: a main flow passage that carries the bulk fluid flow unchanged, and a bypass flow passage that contains the rheometer and carries a small portion of the fluid. This segmentation allows the rheometer to measure viscosity without being intrusive to the main flow, resolving the contradiction between measurement capability and flow rate alteration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bypass flow passage acts as an intermediary that allows the rheometer to interact with the fluid indirectly. Instead of placing the rheometer directly in the main flow path where it would alter flow rate, the system uses the bypass passage as a mediator to extract a sample for measurement while keeping the main flow unchanged.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If viscosity measurement is performed at constant flow rate, then operational stability is maintained, but real-time rheological property determination becomes difficult due to varying viscosity over time

Engineering Contradiction:

Improveflow rate stabilityVSAvoidreal-time viscosity determination

Core Design Contradiction:

Stability of the object's compositionVSMeasurement precision

Solution Approach 1:

The system dynamically adjusts the bypass flow rate using a variable flow restrictor while maintaining constant main flow rate. This allows the rheometer to measure viscosity at different shear rates in real-time without disrupting the overall operational stability of the pumping system, resolving the contradiction between flow rate stability and real-time measurement capability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system uses feedback from viscosity measurements to adjust the variable flow restrictor, enabling real-time determination of rheological properties. The measured viscosity data feeds back into the control system, which adjusts the bypass flow rate to maintain optimal measurement conditions while keeping the main flow rate constant.

Inventive Principle:

Principle #23Feedback

3Measurement precision

If non-Newtonian fluid behavior is accounted for, then measurement accuracy improves, but system complexity increases due to variable flow restrictors and multiple passages

Engineering Contradiction:

Improverheological parameter accuracyVSAvoidapparatus structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The bypass flow passage serves multiple functions: it carries fluid to the rheometer for measurement, allows variable flow rate adjustment for different shear rate measurements, and maintains independence from the main flow system. This multi-functionality reduces the need for additional separate components, offsetting the complexity introduced by the variable flow restrictor.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 apparatus allows for accurate, real-time measurement of rheological parameters, including viscosity, at various shear rates, enhancing the control and efficiency of well operations by accounting for non-Newtonian fluid behavior.

Implementation Method 1

A mass flowmeter is connected in the bypass flow passage

Methodology Applied

Scientific EffectMass flow measurement:

Implementation Method 2

variable flow restrictors to measure rheological parameters without altering the pump flow rate

Methodology Applied

Scientific EffectFlow restriction:

Implementation Method 3

at least one viscometer is connected in the bypass flow passage

Methodology Applied

Scientific EffectViscometry: Viscometer

Implementation Method 4

A first differential pressure sensor is connected across the bypass flow passage

Methodology Applied

Scientific EffectDifferential pressure measurement:

Data Source

PatentUS12222268B1Non-intrusive rheometer for use in well operations

Publication Date: 2025.02.11 WEATHERFORD TECHNOLOGY HOLDINGS LLC

AI summary

A method of determining viscosity can include connecting a bypass flow passage in parallel with a main flow passage, connecting a mass flowmeter and a variable flow restrictor in the bypass flow passage, and connecting at least one viscometer to the bypass flow passage. A rheology measurement apparatus can include a bypass flow passage connected in parallel with a main flow passage, a mass flowmeter connected in the bypass flow passage, and a pipe viscometer connected in the bypass flow passage. Another bypass flow passage may be connected in parallel with the main flow passage, with another mass flowmeter connected in the second bypass flow passage.