ARRANGEMENT AND METHOD FOR DETECTING FLUID INFLUX AND/OR LOSS IN A WELL BORE
An arrangement and method for more accurately detecting well bore fluid kicks and/or losses by coupling a fluid flow measurement device to a substantially vertical tubular, such as a bell nipple or marine riser, to more accurately determine the flow rate of fluid flowing out of the well bore. Well bore fluid kicks and/or fluid losses are preferably detected by comparing the determined flow rate of fluid flowing out of the well bore and the flow rate of fluid injected into the well bore for any difference indicative of a well bore fluid kick or loss event.
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1. Field of the Invention
This invention relates generally to an arrangement and method for detecting kicks (i.e., fluid influxes) and fluid losses from an oil and/or gas well. Specifically, the invention relates to an arrangement and method for accurately determining the fluid flow rate exiting a petroleum well by measuring fluid flow rate through a substantially vertical tubular, such as a bell nipple or marine riser, positioned near the top of the drill string.
2. Description of the Related Art
During the drilling of subterranean wells, a fluid (“mud”) is typically circulated through a fluid circulation system comprising a drilling rig and fluid treating equipment located substantially at or near the surface of the well. The fluid is pumped by a fluid pump through the interior passage of a drill string, through a drill bit and back to the surface through the annulus between the well bore and the drill string.
A primary function of the fluid is to maintain a primary barrier inside the well bore to prevent formation fluids from flowing to surface. A blow-out preventer (BOP), which has a series of valves that may be selectively opened or closed, provides a secondary barrier to prevent formation fluids from flowing uncontrolled to surface. To achieve a primary barrier inside the well bore using the fluid, the hydrostatic pressure of the fluid is maintained higher than the formation fluid pressure (“pore pressure”). Weighting agents may be added to the fluid to increase the fluid density, thereby ensuring that the hydrostatic pressure is always above the pore pressure. If, during drilling of the well bore, a zone is encountered having a higher pore pressure than the fluid pressure inside the well bore, an influx of formation fluid will be introduced into the well bore. Such occurrence is an undesirable event and is known as taking a “kick.” This same situation can occur not only during drilling, but also during completion, work-over or intervention.
When a kick is taken, the invading formation fluid and/or gas may “cut,” or decrease, the density of the fluid in the well bore annulus, such that an increasing amount of formation fluid enters the well bore. Under such circumstances, control of the well may be lost due to breach of the primary barrier. Such an occurrence may be noted at the drilling rig in the form of: (1) a change in pressure in the well bore annulus, (2) a change in fluid density, and/or (3) a gain in fluid volume in the fluid system tanks (“pit volume”).
Numerous arrangements and methods for detecting kicks (i.e., fluid influxes) and/or fluid losses while drilling wells or conducting well operations, workovers, completions, and interventions are known to those skilled in the art. Most of these arrangements and methods monitor the variation in fluid volume that is returned to the fluid/mud system tanks over time as an indicator of a kick or loss event. Using current arrangements and methods, however, this indicator is known to be inaccurate and may also be delayed, because a certain amount of volume is required for detection (i.e., typically over ten barrels). The oil and gas industry has attempted to develop improved methods of detecting kicks and losses in order to minimize their detection time as well as their fluid volume. Most of the improved methods measure the return flow rate at the return flow line and compare the measured return flow rate with the injected flow rate. Under normal circumstances the fluid flow rate into and out of the well bore should be the same (i.e., the differential flow rate should be zero). When a deviation is noted it is typically an indication of either a fluid gain or loss. The placement of flow rate meters on the return flow line from the well bore to measure the return fluid flow has been suggested but such measurements are not necessarily accurate because the return flow line is an open channel and is not always full of fluid. Therefore, the oil and gas industry has come to distrust rig kick detection systems based on this approach.
Another suggested approach is Managed Pressure Drilling (MPD). This method uses a closed-loop system and a flow rate meter on the return line to accurately measure the flow rate out of the well bore. The accuracy in such systems is very good, allowing the detection of a very small differential change in flow rate as well as the detection of the differential change almost immediately after the start of the kick or loss. The improved accuracy and speed of detection in MPD methods is due to the fact the well is closed and the fluid system is under pressure. The limitation posed by these systems is the amount of equipment that must be installed on a rig and kept for maintenance (e.g., to change the elements used on the rotating control heads for maintaining the well closed). This prevents the widespread use of these systems/methods, thus restricting their application to challenging wells, and only for the drilling phase. However, well control problems occur on a daily basis around the world. Such well control problems occur not just during drilling, but also during other operations.
Considering the aforementioned difficulties associated with the current strategies of detecting kicks (i.e., fluid influxes) and/or fluid losses while drilling wells or conducting well operations, workovers, completions, and interventions, an improved arrangement and method will provide several advantages.
3. Identification of Objects of the Invention
An object of the invention is to accomplish one or more of the following:
Provide an arrangement and method to improve detection of kicks and/or fluid losses from an oil and/or gas well;
Provide an arrangement and method for more accurately determining the flow rate of fluid flowing out of a well bore;
Provide an arrangement and method for measuring the flow rate of fluid flowing through a substantially vertical tubular positioned between a well blowout preventer and a return flow line;
Provide an arrangement and method for determining the flow rate of fluid flowing through a substantially vertical tubular while a drill string is positioned therein;
Provide an arrangement and method for measuring the flow rate of fluid flowing through a bell nipple; and
Provide an arrangement and method for measuring the flow rate of fluid flowing through a marine riser.
Other objects, features, and advantages of the invention will be apparent to one skilled in the art from the following specification and drawings.
SUMMARY OF THE INVENTIONThe objects identified above, along with other features and advantages of the invention are incorporated in an arrangement and method for more accurately detecting kicks (i.e., fluid influxes) and/or fluid losses while drilling wells or conducting well operations, workovers, completions, and interventions. In a preferred implementation of the arrangement and method, a fluid flow measurement device is coupled to a substantially vertical tubular, such as a bell nipple or marine riser, disposed between the blowout preventer and the return flow line of a drilling system. The fluid flowing out of the well bore passes through the substantially vertical pipe prior to flowing to the surface fluid/mud tanks via the return flow line. Thus, the fluid flow rate measurement device is arranged and designed to measure the flow rate of fluid exiting the well bore. Measuring the fluid flow rate through the substantially vertical pipe facilitates the accurate measurement of the fluid flow rate, because the substantially vertical pipe is full of fluid when fluid is flowing therethrough and the flowing fluid has a hydrostatic pressure acting upon it due to the fluid above the measurement point.
The fluid flow measurement device of a preferred implementation is an ultrasonic flow rate meter having at least two transducers disposed on the outer surface of the substantially vertical tubular. The transducers are disposed on the substantially vertical tubular such that the ultrasonic signal, which is transmitted between the transmitter and the receiver of each transducer, passes through the annulus formed between the substantially vertical tubular and a drill string disposed therethrough. The transducers are preferably separated by a vertical distance greater than the length of a drill pipe connection, also known as a tool joint. The drill pipe connections of the drill string have a larger diameter than the surround drill pipe segments. Thus, when a drill string is disposed through the substantially vertical tubular, the annulus between the outer surface of the drill string and the inner wall of the substantially vertical tubular is reduced at the drill pipe connections. Therefore, a vertical separation between transducers of greater than the length of a drill pipe connection ensures that at least one of the transducers accurately measures the flow rate of the fluid flowing through the annulus (i.e., at least one transducer measures the annular flow rate that is not affected by a drill pipe connection). The transducers may be disposed about the substantially vertical tubular such that an ultrasonic signal is transmitted through the annulus on multiple sides of the drill string.
Kick or loss detection is preferably accomplished by comparing the flow rate of fluid pumped into the well bore via the drill string with the flow rate of fluid exiting the well bore through the return flow line. The flow rate of fluid pumped into the well bore is measured using another flow rate measurement device on the injection line. The flow rate of fluid exiting the well bore through the return flow line is measured by the fluid flow measurement device coupled to the substantially vertical tubular. When compared, the fluid flow into the well bore should be approximately equal to the fluid flow exiting the well bore for balanced well operations. Thus, any unexplained deviation or difference between the measured fluid flow rates is an indication that a fluid kick or fluid loss may have occurred.
By way of illustration and not limitation, the invention is described in detail hereinafter on the basis of the accompanying figures, in which:
A preferred implementation of the invention addresses one or more of the deficiencies of the prior art and incorporates at least one of the objects previously identified. Turning to
Fluid pumped into the borehole annulus 42 through the drill string 30 flows upwardly through the borehole annulus 42. The BOP 50 is in fluid communication with the borehole annulus 42 and the fluid exits the borehole annulus 42 into the annular space 44 of the BOP 50. Substantially vertical tubular 40 has an inlet 36 coupled to blow-out preventer 50 and an outlet 38 coupled to return flow line 60. Fluid flowing through the annular space 44 of the BOP 50 enters the annular space 46 of the substantially vertical tubular 40 through inlet 36 and exits through the outlet 38 to the return flow line 60. The return flow line 60 is shown as a sub-horizontal tubular which provides fluid communication to mud tanks 74. As shown in
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Kick or loss detection is preferably accomplished by comparing the flow rate of fluid pumped into the well bore 14 via injection line 76 and drill string 30 with the flow rate of fluid exiting from the well bore 14 through the return flow line 60. The flow rate of fluid pumped into the well bore 14 is typically measured/determined using another (or second) flow rate measurement device 78 on the injection line 76. Such flow rate measurement device 78 may be selected from any type known to those skilled in the art including, but not limited to, a coriolis flow rate meter, an ultrasonic flow rate meter, a magnetic flow rate meter, and/or a laser-based optical flow rate meter. Alternatively, the strokes of the surface fluid/mud pump 72 as a function of time can be measured and used to compute the flow rate of fluid pumped into the well bore 14. As previously described, the flow rate measurement device 20 coupled to the substantially vertical tubular 40 is used to measure/determine the flow rate of fluid exiting the well bore 14. If the well is balanced, the fluid flow into the well bore 14 should be approximately equal to the fluid flow exiting the well bore 14 (or have a difference that is approximately equal to the production rate during underbalanced drilling operations). Therefore, upon comparison, any unexplained deviation or difference between the measured fluid flow rates is an indication that a fluid kick or fluid loss may have occurred. A conventional response to any indication of a fluid kick or fluid loss is to close the BOP 50, thereby closing the well bore annulus 42 from atmosphere. One or more of the implementations described herein permit corrective action to be taken sooner, thereby reducing the chance of a loss of well control and its potential adverse effects.
The Abstract of the disclosure is written solely for providing the United States Patent and Trademark Office and the public at large with a means by which to determine quickly from a cursory inspection the nature and gist of the technical disclosure, and it represents one preferred implementation and is not indicative of the nature of the invention as a whole.
While some implementations of the invention have been illustrated in detail, the invention is not limited to the implementations shown; modifications and adaptations of the disclosed implementations may occur to those skilled in the art. Such modifications and adaptations are in the spirit and scope of the invention as set forth in the claims hereinafter:
Claims
1. An arrangement (10, 12) for detecting a well bore fluid kick or loss comprising:
- a drill string (30) having a drill bit (34) at a distil end portion arranged and designed to drill a well bore (14), said drill bit creating a well bore annulus (42) between said drill string and an inner surface of said well bore as said well bore is drilled;
- a blowout preventer (50) in fluid communication with said well bore annulus and arranged and designed to close said well bore annulus from atmosphere in response to an indication of a fluid influx event;
- a substantially vertical tubular (40) fluidly coupled to said blowout preventer and in fluid communication therewith, said substantially vertical tubular having a flow line (60) fluidly coupled to an outlet (38) thereof, said substantially vertical tubular and said flow line arranged and designed to carry fluid exiting said well bore annulus through said blowout preventer; and
- a flow measurement device (20) coupled to said substantially vertical tubular between said blowout preventer and said flow line, said flow measurement device arranged and designed to determine a flow rate of fluid flowing through said substantially vertical tubular.
2. The arrangement of claim 1 wherein,
- said substantially vertical tubular is a bell nipple.
3. The arrangement of claim 1 wherein,
- said substantially vertical tubular is a marine riser.
4. The arrangement of claim 1 wherein,
- said flow measurement device is an ultrasonic flow rate meter.
5. The arrangement of claim 4 wherein,
- said ultrasonic flow rate meter has at least two transducers (22).
6. The arrangement of claim 5 wherein,
- said ultrasonic flow rate meter has two transducers (22) which are disposed on said tubular and separated from each other by a vertical distance (24).
7. The arrangement of claim 6 wherein,
- said vertical distance is greater than a length of a drill pipe connection (32).
8. The arrangement of claim 1 further comprising,
- another flow rate measurement device (78) coupled to a fluid injection line (76) in fluid communication with said drill string disposed in said well bore, said another flow rate measurement device arranged and designed to determine another flow rate of fluid flowing through said fluid injection line.
9. A method for detecting a well bore fluid kick or loss comprising the steps of:
- coupling a flow rate measurement device (20) to a substantially vertical tubular (40), said substantially vertical tubular fluidly coupled to a blowout preventer (50) which is in fluid communication with a well bore (14), said substantially vertical tubular having a flow line (60) coupled to an outlet (38) thereof, said substantially vertical tubular and said flow line arranged and designed to carry fluid exiting said well bore through said blowout preventer, said flow rate measurement device arranged and designed to determine a flow rate of fluid flowing through said substantially vertical tubular between said blowout preventer and said flow line;
- determining said flow rate of fluid flowing through said substantially vertical tubular using said flow rate measurement device coupled to said substantially vertical tubular between said blowout preventer and said flow line; and
- comparing said determined flow rate of fluid flowing through said substantially vertical tubular and a determined flow rate of fluid flowing into said wellbore for any difference indicative of a well bore fluid kick or loss.
10. The method of claim 9 wherein,
- said substantially vertical tubular is a bell nipple.
11. The method of claim 9 wherein,
- said substantially vertical tubular is a marine riser.
12. The method of claim 9 wherein,
- said flow rate measurement device is an ultrasonic flow rate meter.
13. The method of claim 12 wherein,
- said ultrasonic flow rate meter has at least two transducers (22).
14. The method of claim 13 wherein,
- said ultrasonic flow rate meter has two transducers (22) which are disposed onto said substantially vertical tubular and separated from each other by a vertical distance (24).
15. The method of claim 14 wherein,
- said vertical distance is greater than the length of a drill pipe connection (32).
16. The method of claim 9 further comprising the steps of,
- coupling another flow rate measurement device (78) to a fluid injection line (76) in fluid communication with a drill string (30) disposed in said well bore, said another flow rate measurement device arranged and designed to determine another flow rate of fluid flowing through said fluid injection line into said drill string, and
- determining said another flow rate of fluid flowing through said fluid injection line into said drill string using said another flow rate measurement device, and wherein
- said determined flow rate of fluid flowing into said wellbore is equal to said another flow rate of fluid flowing through said fluid injection line into said drill string.
17. An arrangement (10, 12) for measuring flow rate of fluid exiting a well bore, said arrangement comprising:
- an ultrasonic flow rate meter (40) having at least two transducers (22) disposed about a substantially vertical tubular (40), said substantially vertical tubular coupled to a wellhead (52) and in fluid communication with a well bore (14), said at least two transducers having a vertical separation (24) therebetween and arranged and designed to determine a flow rate of fluid passing through said substantially vertical tubular from said well bore.
18. The arrangement of claim 17 wherein,
- said substantially vertical tubular is a bell nipple.
19. The arrangement of claim 17 wherein,
- said substantially vertical tubular is a marine riser.
20. The arrangement of claim 17 wherein,
- said vertical separation is greater than the length of a drill pipe connection (32).
Type: Application
Filed: Aug 11, 2010
Publication Date: Feb 16, 2012
Applicant:
Inventors: HELIO SANTOS (Reading), Erdem Catak (Katy, TX), Jason Hannam (Katy, TX)
Application Number: 12/854,674
International Classification: E21B 47/10 (20060101); E21B 33/06 (20060101);