Abstract:
A drilling fluid analyzing apparatus has at least two sensors is used to analyze drilling fluid that contains cuttings. The sensors are mounted vertically spaced in a well riser and in communication with well return fluid. The sensors convert the pressure exerted by the return fluid to signals that are then conveyed to a processor. The processor determines the density of the return fluid, and the fluid density is indicative of borehole cleaning efficiency. Two additional sensors may be added to the drilling fluid input mud pipe to sense the pressure exerted by the drilling mud before it is contaminated with cuttings.

Description:
RELATED APPLICATIONS 
     This application is related to United States Application for Letters Patent Ser. No. 09/197,300 filed on Nov. 20, 1998. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to a method and system for continuously measuring the efficiency of drilling fluid. More specifically, the invention relates to a system and method for detecting cuttings accumulation and washout in wellbore during drilling operations by analyzing the return fluid containing drilling mud and cuttings exiting the wellbore. 
     2. Description of the Related Art 
     Drilling fluids are employed when drilling boreholes into subterranean formations. The drilling fluid “mud” consists of mixture of liquids and solids to provide special properties to better perform several primary functions in a drilling well. Drilling fluids lift the formation cuttings to the surface, control subsurface pressure, lubricate the drill string and bit, aid bottom-hole cleaning, aid formation evaluation, and provide protection to formation productivity. 
     One of the primary functions of the drilling fluid is the control of the formation pressure. The hydrostatic pressure exerted by the mud column, which is controlled by the density of the drilling fluid, is maintained above the pressure of the formation. If the formation pressure exceeds the pressure exerted by the mud column, formation fluid may enter the wellbore, causing a kick, which is any unscheduled entry of formation fluid into the wellbore. This results in a gain in the flow rate of the returning fluid. Additionally, the drilling fluid may incur losses due to the presence of a fracture in the formation. Fractures can result in loss of the drilling fluid, which results in a loss of the fluid flow rate at the surface. It is important to continuously monitor for the pressure of kicks and the fracture during drilling of wellbores. There are several methods and systems well known in the art that measure flow rate directly with various sensors. 
     Another primary purpose of the drilling fluid is to lift cuttings from the wellbore. The drilling mud is circulated down the drill string, through the bit, and returns to the surface through the annular space between the drill string and the wellbore wall. The mud returning to the surface is known as return fluid comprising drilling mud, formation particles called cuttings, and possibly some formation fluids. The drilled cuttings are picked up at the bit and returned to the surface for separation from the mud and for disposal. This removal of the drilled solids from the mud stream is critical to the subsequent reconditioning of the mud for recirculation in the well. 
     To control and improve drilling performance, evaluation of wellbore condition is important. Keeping the hole clean, especially in extended reach wells, is a key issue as cuttings accumulation in the annulus can contribute to, if not directly cause, pipe sticking and twist-offs. This is a concern when drilling a deviated well since a bed of cuttings is almost always formed on the lower side of the drill pipe. By measuring the cuttings discharge at the surface, the buildup of cuttings in the well can be detected early and remedial action taken to prevent a catastrophic failure. 
     Another obstacle encountered in drilling operations is washout. Washout is excessive borehole enlargement caused by solvent and erosion action by the drilling fluid. Washout can cause severe damage to the formation, contaminate the connate formation fluids, and waste costly drilling mud. Early detection through the measurement of cuttings exiting the wellbore can also help the mitigation of this problem. 
     In typical cuttings evaluation, the cuttings from the well are discharged over one or more shale shaker screens to separate them from the drilling mud, and all cuttings coming from the shakers are weighed. With expected cuttings density known by the user, the expected volume of the cuttings is calculated and the volume removed is compared to the volume calculated. Thus hole-cleaning efficiency is evaluated. 
     Currently the main types of mud out weight sensors used are a strain gauge and suspended heavy weight system, systems using differential pressure plates in the mud pit, and radioactive source sensors. Some of the mud adheres to the cuttings and is carried over with the cuttings discharged from the shale shaker. This portion of mud is lost to the mud system, which has been reported to be as high as two barrels of mud for every barrel of cuttings. The mud lost in the cuttings causes accuracy problems with the first two sensor types. The third system, although more accurate, is costly and requires certification and approval. The first two systems are not accurate enough for the cuttings removal performance application because of the settlement of the cuttings in the pits. 
     SUMMARY OF THE INVENTION 
     An object of the present invention is to provide an accurate, simple arid robust sensor system to evaluate hole cleaning performance. Two highly accurate pressure sensors are installed vertically displaced in a well riser to sense the pressure exerted by the return fluid including drilling mud and cuttings. Another object is to provide a processor for receiving signals from the sensors and for processing the data to determine hole cleaning performance. The advantage in measuring the return fluid is that the flow out including the cuttings is homogenous in the riser and no settlements occur. 
     In another embodiment, two additional sensors are provided to measure the drilling mud as it enters the well. With two sensors measuring return fluid pressure and two sensors measuring the pressure of drilling fluid entering the well, a processor can calculate efficiency based on more measured parameters. The processed data is an indication of well cleaning efficiency that can allow for early detection of washout or cuttings accumulation. 
     In another embodiment, sensors provided in a riser during tripping operations are used in conjunction with other sensors, such as flow rate sensors, to detect washouts and kick through the measurement of mud parameters entering the wellbore. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For detailed understanding of the present invention, references should be made to the following detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings, in which like elements have been given like numerals and wherein: 
     FIG. 1 is a schematic diagram of a drilling fluid flow measurement system for use during the drilling of a wellbore. 
     FIG. 2 is a simplified schematic used to show the relationship between variables used in calculating mud density and the present invention. 
     FIG. 3 is a schematic diagram of a drilling fluid flow measurement system for use during the drilling of a wellbore wherein an additional sensor is added to a vertical inflow line. 
     FIG. 4 is the system of FIG. 1 with a secondary pump during tripping operation and an associated mud weight sensor according to the present invention for determining mud weight entering the wellbore. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1 is a schematic elevational diagram of a drilling fluid flow system  100 . The system  100  shown includes a drill string  115  that includes a tubing  116  that has a drill bit  118  at its bottom end. To drill the wellbore  110 , a drilling fluid  120  is pumped from a source (pit)  140  into the tubing  116  by one or more mud pumps  135   a - 135   c . The drill bit  118  is rotated by a mud motor (not shown) and/or by rotating the tubing  116  at the surface by a suitable motor (not shown). The drill bit  118  cuts the rock into small fragments  124  (referred to in the art as the “cuttings”). The drilling fluid  120  discharges at the drill bit bottom  118   a  and returns to the surface  102  via the annular space  122  (also referred to as the annulus) carrying the cuttings  124 . The returning drilling fluid is denoted by the numeral  126 . 
     The returning drilling fluid  126  passes into a riser  128 , and then into a generally horizontal out flow or return line  130 . The flow line  130  has a sufficiently large cross-sectional area, which allows the returning fluid  126  to flow without filling the entire outflow line  130 . This leaves sufficient area above the fluid level  127  for the installation of sensors  155 . The fluid  126  returning from the wellbore may be a three phase fluid: liquid, gas and solids. Any gas flows above the fluid line  127 . Some solids settle at the flow line  130 . The fluid  126  from the return line  130  passes to a shaker that removes the cuttings  124 . The fluid  126  is then processed in a processor  145  and passed to an active pit  140  that serves as the source of the clean fluid  120 . 
     In the present invention, mud weight out sensor  165  is suitably installed in the riser  128 , which provides measurements for determining the density of the fluid  126  returning into the flow line  130 . The mud weight out sensor is preferably a set of two pressure sensors P 2  and P 1 . 
     A separate flow in sensor is preferably installed to determine the output of each pump  135   a - 135   c . In the system  100 , sensors  160   a - 160   c  respectively placed in the in-flow lines  136   a - 136   c  provide fluid output of each of the pumps  135   a - 135   c . Alternatively, the sensors  160   a - 160   c  may be installed in the output lines  137   a - 137   c . Any suitable sensor may be used for measuring the flow through the pumps  135   a - 135   c . Details of sensors such as these are detailed in the abovementioned related patent application, Ser. No. 09/197,300 filed on Nov. 20, 1998. The entire content of said application is hereby incorporated herein by reference. 
     As noted above, one of the primary functions of the drilling fluid  120  is the control of the formation pressure. The hydrostatic pressure exerted by the mud column  180  is maintained above the pressure of the formation  170 . This is controlled by the density of the drilling fluid  120 . Drilling fluids also contain a variety of additives. Drilling fluids are selected based on the desired characteristics relating to the density, viscosity, cutting carrying capacity, corrosion resistance, etc. Both water-based and oil-based drilling fluids are used depending upon the specific application. If the formation pressure exceeds the pressure exerted by the mud column  180 , formation fluid  182  may enter the wellbore  110 , causing a kick, which is any unscheduled entry of formation fluid into the wellbore  100 . This results in a gain in the flow rate of the returning fluid  126 . Additionally, the drilling fluid may incur losses due to the presence of a fracture in the formation  170 , such as fracture  184 . This results in loss of the drilling fluid, which results in a loss of the fluid flow rate at the surface. Monitoring of the flow rate of fluids entering and exiting the wellbore is accomplished with sensors  155  and  160   a - 160   c.    
     As noted above, other key functions of the drilling fluid  120  keeping the wellbore  110  clean by removing cuttings  124 , especially in extended reach wells, because cuttings accumulation in the annulus can contribute to, if not directly cause, pipe sticking and twist-offs. This is a concern when drilling a deviated well since a bed of cuttings is almost always formed on the lower side of the drill pipe. By measuring the cuttings discharge at the surface, the buildup of cuttings in the well can be detected early and remedial action taken to prevent a catastrophic failure. 
     Another obstacle encountered in drilling operations, as noted above, is washout. Washout is excessive enlargement of wellbore  110  caused by solvent and erosion action by the drilling fluid  120 . Washout can cause severe damage to the formation, contaminate the connate formation fluids, and waste costly drilling mud. Early detection through the measurement of cuttings  124  exiting the wellbore  110  can also help mitigate this problem. The novelty of the present invention is that highly accurate and inexpensive measurements of pressure differentials in this relatively homogeneous returning fluid  122  including cuttings  124  can be made at the riser  128 . This measurement can lead to the early detection of washouts and hole cleaning problems. 
     Mounted on the riser  128  weight-out sensor  165  are preferably two pressure sensors P 2  and P 1 . These sensors are spaced vertically approximately two meters apart and are in communication with the returning fluid  126  so that the pressure exerted by the returning fluid can be detected and measured. Preferably, the sensors would have a measuring accuracy of 0.01% F.S. or better. The pressure sensors P 2  and P 1  convert the measured pressure to an electrical signal. This signal is then conveyed by conductors  165   a  and  165   b  to a processor  166  that performs an evaluation to determine the density of the returning fluid including cuttings  124 . 
     The dynamic pressure losses over a length interval of approximately two meters can be neglected. The measured pressure values can be evaluated to determine a highly accurate mud out weight including the cuttings  124 . Referring now to schematic in FIG. 2, with the measured pressures P 1 , P 2 , the known vertical separation h of the sensors, and g being the earth gravitational force the mud weight out ñ can be calculated by processor  166  with equation 1.                ρ   out     =       P2   -   P1     gh             (     Equation                 1     )                                
     Knowing the mud weight out, the weight of the removed cuttings can now be calculated with the measured flow out and the flow in over the measured mud weight in and mud weight out. This weight is compared with the expected weight of the cuttings calculated with the known cross section of the bit  118 , rate of penetration and the cuttings density. A cutre factor K is determined as the relation between the measured cuttings weight and the expected cuttings weight, and can be calculated with equation 2:              K   =     4        [           q   out          ρ   out       -       q   in          ρ   in           ROP   *     OD   2        π                   ρ   cuttings         ]               (     Equation                 2     )                                
     Where: 
     ROP=rate of penetration; 
     OD=bit outer diameter; 
     ρ=density; 
     q=flow rate; and 
     K=cutre factor. 
     The cutre factor indicates wash out and hole cleaning problems by K&gt;1 indicating wash out problems and K&lt;1 hole indicating cleaning problems (cuttings accumulation). 
     If the flow out is not measured and no influxes or losses occur, the flow out can be set equal to the flow in for equation 1. For even higher accuracy, the algorithm must take care of circulation lag times, and practical application will dictate if and how the signals must be averaged or filtered. 
     In an alternate embodiment is shown in FIG. 3, return fluid  126  is removed from the borehole  110  and flows through the riser  128  as in the first described embodiment. As in the first embodiment, weight-out sensor  165  comprising pressure sensors P 1  and P 2  detect the return fluid pressure and pass the information to the processor  166  for evaluation. In this embodiment, drilling fluid  120  is evaluated using a mud weight-in sensor  168  comprising preferably two pressure sensors P 4  and P 3 . Mud pumps  135   a - 135   c  pump the drilling fluid  120  from an active pit  140 , and the fluid flows through inflow lines  136   a - 136   c , through one or more mud pumps  135   a - 135   c , and through output lines  137   a - 137   c  before being passed back into wellbore  110  through tube  116 . Prior to being injected back into wellbore  110 , the drilling fluid passes sensors P 4  and P 3  of weight-in sensor  168 . The sensors P 4  and P 3  are spaced vertically approximately two meters apart and are in communication with the drilling fluid  120  so that the pressure exerted by the drilling fluid  120  can be detected and measured. The pressure sensors P 4  and P 3  convert the measured pressure to an electrical signal. Conductors  168   a  and  168   b  convey this signal to the processor  166  that performs the evaluation of the drilling fluid  120  along with the evaluation of the returning fluid  126 . The actual location of the sensors P 4  and P 3  is not critical, so sensors P 4  and P 3  may be located on any oil well drilling component through which drilling mud passes. However, the chosen location must allow for vertical displacement of the sensors. 
     FIG. 4 shows the system  100  of FIG. 1 with a secondary fluid inflow system  300 . This secondary or trip inflow system includes a secondary pump or trip pump  310  that pumps drilling fluid  330  from a trip tank  320  into the annulus  122  of the wellbore  110  via a supply line  322 . The trip pump  310  is usually much smaller than the main mud pumps  135   a - 135   c  because the fluid volume pumped in during tripping is relatively small. The trip pump  310  may be arranged to pump fluid from the tank  120 , eliminating the need for a separate trip tank  320 . A flow measuring apparatus  340  (also referred to herein as a trip flow meter) is connected in line  324  between the trip tank  320  and the trip pump  340 . The trip flow meter may also be installed in the horizontal section  326  of the line  322 . The flow meter  340  provides the volume of the fluid pumped into the wellbore  110  during the tripping operation. In this alternate embodiment of the present invention, mud weight sensors  165  are utilized to determine the weight of the mud  330  being pumped into the wellbore annulus  122 . With the mud weight Mw measured along with the flow rate and the rate and volume of the drill string filled with mud being known, changes in the expected mud parameters are determinable. Changes in fluid volume and pressure entering the well can be used to indicate the presence of washouts or a kick. Appropriate actions may then be taken to preserve the formation and ensure safety of the operation. 
     The foregoing description is directed to particular embodiments of the present invention for the purpose of illustration and explanation. It will be apparent, however, to one skilled in the art that many modifications and changes to the embodiment set forth above are possible without departing from the scope and the spirit of the invention. It is intended that the following claims be interpreted to embrace all such modifications and changes.