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FORNY20-FORNY2020

Flowrate Out Sensor

Alternative title: Flowrate Out Sensor

Awarded: NOK 5.0 mill.

Drilling underground wells is important for extracting energy and natural resources, and now also for the storage of CO2 and potentially Hydrogen. Safe and energy-efficient drilling operations are crucial for more sustainable utilization, to minimize the risk of harm to people and the environment, and to enable the use of subsurface areas that would otherwise not be possible or cost-effective. In recent years, digitalization and new automation solutions for well drilling have led to significant cost and emission reductions, as well as decreased energy consumption. A key reason for this development is the better utilization of real-time information from operations. Advanced software and instrumentation for monitoring and control have been developed to enable the drilling of wells that would otherwise be too challenging, to increase safety, and to utilize natural resources more efficiently and cost-effectively. However, one challenge with the use of new automation solutions is that parts of the drilling process remains insufficiently instrumented, particularly when it comes to measuring the flow rate out of the well. Current measurements for flow rate out of the well have an uncertainty of around 10%, and even higher uncertainty at low rates. Accurate measurement of the flow rate out of the well at all times is crucial for systems that monitor and control drilling operations. A new device for measuring this flow rate is now under development. Previous tests have shown that the device achieves an accuracy as low as 1%. The goal of this project is to verify that the device can handle realistic conditions and is designed to fit existing drilling rigs. Prototypes that meet accuracy and design requirements will be built, and testing will be conducted. The project will also carry out a thorough market analysis to reduce uncertainty related to market potential and the choice of commercialization strategy. Through the project, potential applications outside of well drilling with significant market potential will also be explored.

The project has demonstrated the accuracy and robustness of the sensor's measurement methodology. Should future verification and commercialization efforts succeed, the sensor's most significant and immediate benefit will be its ability to measure potential influxes and losses with high precision, enabling early detection of kicks and losses. While the primary advantage of the sensor is its high-accuracy measurements, its integration with drilling automation software will enhance operational precision, significantly improving safety and reducing costs. As a result, technologies that prevent well control incidents and other drilling problems will become more reliable and accurate, leading to a decrease in non-productive time and technical side-tracks. Potentially also reducing the risk of severe well control situations that can harm personnel and the environment. Additionally, more efficient hole-cleaning procedures will shorten circulation times. Ultimately, reducing well construction costs is a key enabler for advancing other subsurface disciplines such as geothermal energy production and CO2 storage.

Funding scheme:

FORNY20-FORNY2020