Wellbore Fluid Level Monitoring via Air Flow Sensor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
During wellbore drilling, the loss of drilling fluid into loss circulation zones leads to challenges in monitoring the fluid level in the annulus, as existing methods fail to accurately detect fluid levels in real-time, affecting operational efficiency and safety.
Innovation Solution
A wellbore fluid level monitoring system that uses an air flow sensor and computational models to measure air flow rates and determine liquid levels by sensing air flow through a bell nipple, with a sealing mechanism to protect the sensor from liquids and allow measurement only when the fluid level drops, enabling real-time fluid level detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an air flow sensor is installed in the annulus to detect fluid level, then real-time monitoring capability is improved, but the sensor reliability deteriorates due to exposure to drilling fluid
Solution Approach 1:
A sealed housing acts as an intermediary barrier between the air flow sensor and the drilling fluid in the annulus. The housing allows air flow detection while preventing fluid contact, thus maintaining sensor reliability while enabling real-time fluid level monitoring through air flow rate changes
2Reliability
If the air flow sensor is sealed to protect from liquid, then sensor reliability is improved, but the ability to sense air flow deteriorates
Solution Approach 1:
The sealed housing serves as a mediator that transmits air flow information to the sensor while blocking liquid. The housing allows air to pass through and interact with the sensor, enabling air flow detection while maintaining the seal against drilling fluid
Solution Approach 2:
The housing employs sealing mechanisms with flexible elements that can respond to pressure changes from air flow while maintaining liquid tightness, allowing the sensor to detect air flow rate variations without direct fluid exposure
3Productivity
If real-time monitoring is implemented, then operational efficiency is improved, but system complexity increases
Solution Approach 1:
The system utilizes the natural air flow that occurs when fluid levels drop in loss circulation zones, eliminating the need for active pumping or complex mechanical components. The air flow sensor passively detects the flow rate, which directly indicates fluid level changes, providing real-time monitoring with minimal system complexity
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
This system allows for accurate and real-time monitoring of fluid levels in the annulus, enhancing operational efficiency and safety by preventing fluid loss and enabling effective mitigation strategies during loss circulation events.
Implementation Method 1
Air flowing in a downhole direction through a portion of an annulus within the bell nipple below the rotary table responsive to a decrease in a liquid level in the portion of the annulus is sensed
Data Source
AI summary
A wellbore fluid monitoring system includes a housing, a first sealing element, a second sealing element and a sealing unit. The housing is configured to be securely disposed in a portion of an annulus within a bell nipple below a rotary table of a wellbore drilling assembly. The annulus is formed by a drill string of the wellbore drilling assembly and an inner wall of a wellbore being drilled by the wellbore drilling assembly. The housing includes a first open end and a second open end. The housing is configured to house an air flow sensor disposed within the housing. The first sealing element is attached to the first open end of the housing. The first sealing element is configured to seal and unseal the first open end. The second sealing element is attached to the second open end of the housing. The second sealing element is configured to seal and unseal the second open end. The sealing unit is disposed in the portion of the annulus. The sealing unit is connected to the housing, the first sealing element and the second sealing element. The sealing unit is configured to actuate the first sealing element and the second sealing element to seal or unseal the first open end and the second open end, respectively, based on a liquid level in the portion of the annulus.