Well Cleanup Tool with Real-Time Flow Sensor Feedback

Solution Overview

Problem

Current well cleanup tools lack real-time monitoring capabilities to detect issues such as screen clogging or cutting accumulation, which can lead to equipment failure during milling operations, relying on operator intuition or unreliable rules of thumb.

Innovation Solution

Incorporating a flow sensor into the junk basket to detect flow stoppages and communicate issues to the surface in real-time through various signals, allowing for immediate corrective actions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a screen is used to separate cuttings from circulating fluid in a junk basket, then cutting separation efficiency is improved, but the screen can clog with debris causing flow stoppage and equipment failure

Engineering Contradiction:

Improvecutting separation efficiencyVSAvoidscreen clogging risk

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

A flow sensor is installed in the junk basket to detect flow stoppage conditions in real-time. When the sensor detects that flow has stopped or significantly reduced, it triggers an alarm signal to the surface, alerting operators to potential screen clogging or other downhole issues before they cause equipment damage. This feedback mechanism allows for proactive intervention to maintain reliable operation.

Inventive Principle:

Principle #23Feedback

2Reliability

If real-time monitoring is added to detect flow stoppages, then equipment protection capability is improved, but device complexity increases

Engineering Contradiction:

Improveequipment protection capabilityVSAvoidsensor and signaling system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

A flow sensor is installed in the junk basket to detect flow stoppage conditions in real-time. When the sensor detects that flow has stopped or significantly reduced, it triggers an alarm signal to the surface, alerting operators to potential screen clogging or other downhole issues before they cause equipment damage. This feedback mechanism allows for proactive intervention to maintain reliable operation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces complex mechanical monitoring systems with a simple electronic flow sensor and signaling system. The flow sensor electronically detects flow conditions and transmits alarm signals to the surface, eliminating the need for complex mechanical indicators or manual inspection procedures while providing reliable real-time monitoring capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If the mill operates continuously without monitoring, then productivity is maintained, but the risk of overheating or sticking increases

Engineering Contradiction:

Improvecontinuous operation capabilityVSAvoidmill overheating and sticking risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

A flow sensor is installed in the junk basket to detect flow stoppage conditions in real-time. When the sensor detects that flow has stopped or significantly reduced, it triggers an alarm signal to the surface, alerting operators to potential screen clogging or other downhole issues before they cause equipment damage. This feedback mechanism allows for proactive intervention to maintain reliable operation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The flow sensor provides advance warning of flow stoppage conditions before they escalate to critical levels that could cause mill overheating or sticking. By detecting flow reductions early and triggering alarms, the system enables operators to take preliminary corrective actions such as adjusting drilling parameters or clearing debris, preventing harmful conditions from developing and allowing continuous safe operation.

Inventive Principle:

Principle #10Preliminary action

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 timely intervention to prevent equipment damage by providing real-time feedback on flow changes, allowing operators to address problems before they escalate, thereby ensuring continuous operation and reducing the risk of mill overheating or sticking.

Implementation Method 1

Incorporating a flow sensor into the junk basket to detect flow stoppages

Methodology Applied

Scientific EffectFlow detection:

Implementation Method 2

The eductor 14 reduces pressure in chamber 18 all the way down to the lower inlet 20 on the tool 12... well fluid below tool 12 that is sucked in due to the venture effect of the eductor 14

Methodology Applied

Scientific EffectVenturi effect: Venturi Effect

Data Source

PatentUS7472745B2Well cleanup tool with real time condition feedback to the surface

Publication Date: 2009.01.06 BAKER HUGHES CO

AI summary

A flow sensor is incorporated into a junk basket to sense a flow stoppage due to a plugged screen or plugged cuttings ports in a mill. The sensor triggers a signal to the surface to warn personnel that a problem exists before the equipment is damaged. The sensor signal to the surface can take a variety of forms including mud pulses, a detectable pressure buildup at the surface, electromagnetic energy, electrical signal on hard wire or radio signals in a wifi system to name a few options. Surface personnel can interrupt the signal to take corrective action that generally involves pulling out of the hole or reverse circulating to try to clear the screen or mill cuttings inlets. Other variables can be measured such as the volume or weight or rate of change of either and a signal can be sent to the surface corresponding to one of those variables to allow them to be detected at the surface in near real time.