Pup Joint Sensor Modules for Wellbore Kick Detection

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Solution Overview

Problem

During drilling operations, the inability to effectively detect kicks in a wellbore leads to potential well blowouts, which pose hazards to personnel and equipment, and can result in costly consequences due to the invasive nature of formation fluids into the wellbore.

Innovation Solution

Deployment of sensor-equipped pup joints along the drill string, featuring internal and external sensor modules that measure properties of drilling fluids, allowing for real-time comparison against pre-determined threshold values to detect kicks and alert operators, thereby enabling timely adjustments to prevent wellbore instability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional drilling operations are conducted without real-time kick detection systems, then device complexity is reduced, but the ability to detect kicks timely is insufficient leading to potential well blowouts

Engineering Contradiction:

Improvekick detection capabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The drill string is divided into multiple pup joints, each equipped with independent sensor modules. This segmentation allows distributed monitoring of drilling fluid properties at different depths, enabling localized detection of kicks while maintaining overall system reliability without requiring a single complex centralized system

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sensor modules autonomously measure drilling fluid properties and compare them against threshold values without requiring continuous surface intervention. The system self-monitors and self-diagnoses kick conditions, reducing the need for complex surface-based detection infrastructure while improving reliability

Inventive Principle:

Principle #25Self-service

2Measurement precision

If multiple sensor modules are deployed in pup joints along the drill string, then real-time kick detection accuracy is improved, but device complexity and cost increase

Engineering Contradiction:

Improvekick detection accuracyVSAvoidnumber of sensor modules

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

Each sensor module is designed as a universal, multi-functional unit that can detect various kick types (gas, oil, water) by measuring multiple drilling fluid properties. This standardized approach improves detection accuracy across different scenarios while avoiding the complexity of deploying specialized sensors for each kick type

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system detects kicks by monitoring changes in drilling fluid parameters (density, resistivity, acoustic velocity) rather than requiring complex direct detection mechanisms. This parameter-based approach improves measurement precision while maintaining relatively simple sensor designs that measure fundamental fluid properties

Inventive Principle:

Principle #35Parameter changes

3Loss of time

If real-time monitoring of drilling fluid properties is implemented, then response time to kicks is reduced, but energy consumption and operational complexity increase

Engineering Contradiction:

Improveresponse timeVSAvoidenergy consumption

Core Design Contradiction:

Loss of timeVSUse of energy by moving object

Solution Approach 1:

The sensor modules perform measurements at periodic intervals rather than continuously, monitoring drilling fluid properties at regular sampling rates. This periodic monitoring reduces energy consumption compared to continuous monitoring while still providing timely kick detection by capturing parameter changes at critical moments

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The system implements feedback by comparing measured drilling fluid properties against pre-determined threshold values and immediately triggering alerts when kicks are detected. This feedback mechanism enables rapid response to kicks without requiring continuous high-energy processing, as the system only activates intensive monitoring and alerting when parameter changes indicate potential kick conditions

Inventive Principle:

Principle #23Feedback

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 provides accurate and timely detection of kicks, reducing the risk of well blowouts and enhancing drilling safety by allowing for immediate adjustments to drilling fluid density, thus improving operational efficiency and reducing the need for surface calibration and physical sampling.

Implementation Method 1

The one sensor module measures parameters (e.g., pressure, temperature, resistivity, dielectric constant, density, or acoustic velocity) indicative of the properties of the drilling fluid inside the drill string

Methodology Applied

Scientific EffectPressure measurement: