US 12,286,848 B2
System and method to detect and measure fluid flow in the return line during drilling activities
Krzysztof Karol Machocki, Aberdeen (GB); and Sakethraman Mahalingam, Aberdeen (GB)
Assigned to SAUDI ARABIAN OIL COMPANY, Dhahran (SA)
Filed by SAUDI ARABIAN OIL COMPANY, Dhahran (SA)
Filed on Aug. 24, 2023, as Appl. No. 18/455,543.
Prior Publication US 2025/0067133 A1, Feb. 27, 2025
Int. Cl. E21B 21/08 (2006.01); E21B 21/06 (2006.01)
CPC E21B 21/08 (2013.01) [E21B 21/065 (2013.01)] 19 Claims
OG exemplary drawing
 
1. A system for monitoring fluid flow conditions on a return flow line, comprising:
a return flow line in fluid communication with a wellbore;
a shaker having one or more screens configured to filter a fluid;
a header box coupled to the shaker and in fluid communication with the return flow line;
a contactless flow sensor, comprising a camera, facing an interior of the header box or an outlet of the return flow line proximate the header box and configured to determine a fluid flow rate based on a fluid level in the header box, the return flow line, or both;
a data gathering and analyzing unit operatively coupled to the contactless flow sensor, wherein the data gathering and analyzing unit determines a current operational status or a hazardous operational status based on the fluid flow rate and a mud pump speed;
a dye sprayer coupled to the header box and directed towards an interior of the header box, wherein the dye sprayer sprays a dye on the fluid in the header box to improve camera visibility of a mud level for the contactless flow sensor; and
a control panel operatively coupled to the data gathering and analyzing unit, wherein the control panel comprises:
a human machine interface (HMI) configured to display the fluid flow rate, the mud pump speed, and the current operational status or the hazardous operational status; and
one or more notification instruments configured to activate based on the hazardous operational status.