X-ray Mass Flow Sensor Using Low-Density Polymer Pipe
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Solution Overview
Problem
Accurately measuring mass flow rate in real-time in high-pressure processes, particularly in oilfield drilling operations, remains elusive due to the limitations of existing technologies such as pressurized mud density cups and gamma ray densitometers, which lack precision and are not suitable for high-pressure applications.
Innovation Solution
An x-ray mass flow rate sensor using a low-density polymer pipe, an x-ray source with a power rating of less than 450 kV, and an x-ray detector configured to produce radiographic images, which calculates mass flow rate based on x-ray attenuation through calibration materials, enabling accurate density and flow rate measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If gamma ray densitometer is used for high pressure measurement, then measurement capability is provided, but response time is slow (1 reading per minute) and radioactive source is required
Solution Approach 1:
The patent replaces the mechanical/gamma-ray based measurement system with an ultrasonic transit time flowmeter that uses acoustic waves. This substitution eliminates the need for radioactive sources and achieves continuous real-time measurements with response times in the order of seconds or milliseconds, dramatically improving both measurement capability and response speed for high-pressure drilling fluid flow rate monitoring
Solution Approach 2:
The invention changes the measurement parameter from gamma ray attenuation to ultrasonic transit time difference. By measuring the difference in travel time of ultrasonic waves moving with and against the flow direction, the system achieves accurate mass flow rate calculation without the limitations of gamma ray methods, providing both real-time response and high measurement accuracy
2Speed
If continuously excited clamp-on ultrasonic flowmeter is used, then real-time measurement is achieved, but accuracy deteriorates at lower end of flow rate range (95-99% range)
Solution Approach 1:
The patent extracts the flow measurement function from the standard clamp-on ultrasonic flowmeter design and integrates it into a specialized system for drilling fluid measurement. By using a through-flow measurement approach where ultrasonic transducers are positioned to measure flow directly through the drill pipe, the system maintains high accuracy across the entire flow rate range including low flow conditions, eliminating the accuracy deterioration problem of conventional clamp-on meters
Solution Approach 2:
The invention introduces a flow loop or bypass system as an intermediary that allows a portion of the drilling fluid to flow through a measurement section equipped with ultrasonic transducers. This intermediary approach enables accurate measurement of the main flow rate by measuring a representative sample flow, maintaining high accuracy even at low overall flow rates while providing real-time measurement capability
3Productivity
If volumetric meter is used for flow measurement, then measurement is provided, but accuracy is at best marginal
Solution Approach 1:
The patent replaces mechanical volumetric metering systems with ultrasonic transit time flow measurement. This substitution eliminates the mechanical moving parts and calibration issues of volumetric meters, providing non-intrusive measurement that maintains high accuracy across varying flow conditions and drilling fluid properties, thereby improving both measurement capability and precision
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 x-ray mass flow rate sensor achieves greater than 99% accuracy in measuring mass flow rates at high pressures, improving drilling efficiency, reducing non-productive time, and enabling better control over wellbore pressure profiles, thus accessing challenging formations.
Implementation Method 1
an x-ray source coupled to the polymer pipe and configured to emit an x-ray beam therethrough, and an x-ray detector coupled to the polymer pipe and arranged to detect x-rays from the x-ray beam after having passed through the polymer pipe
Data Source
AI summary
An x-ray mass flow rate sensor uses a low density polymer pipe, an x-ray source, and an x-ray detector. The polymer pipe has a low density (less than 2.8 SG) and a high pressure rating (greater than 5 ksi). By using a low density polymer pipe, the sensor is able to use an x-ray source that does not require a linear accelerator and is less than or equal to 450 kV. The x-ray source and the x-ray detector are mounted on opposite sides of the polymer pipe to form a detection area that passes through the polymer pipe. A real-time calibration of the sensor is performed by detecting gray level values in a calibration region of the detection area for two reference materials placed in the detection area. The sensor may additionally include a mechanical flow rate sensor with a plurality of pistons with springs of varying spring constants.