e

IADCISPE
lADC/SPE 17228
Development and Field Testing of a High-Accuracy Full-Bore
Return Flow Meter
by H,K. Johnsen, Petreco AfS; P, Skalle, * U. of Trondheim; A.L. Podio, * U. of Texas;
and G. Sirevaag and A. Vigen, Statoil A/S
SPE Membsrs

-ml 1988, lADC/SPE Drilling Conference

This paper was prepared for presentation at the 1988 lADC/SPE Drilf@ Conference held in Dallas, Texas, February 28-March 21988.
This paper was selected for presentation by an lADC/SPE Program Committee following review of information contained in an abalracl submitted by
the author(a). Contents of the Paper, aa presented, have not been review@ bY the SWietY of petroleum En9ineere or international A==ialion of Drill
ing Contractor and are subject to correction by the author(a), Tha material, as presented, does not naceaaarily raflect any position of tha IADC or
SPE, Ila officere, or members. Papera presented at lADC/SPE mwfinga are subject to publication review by Editorial Committals of the IADC and
SPE. Permission to copy ie restricted to an abstract of not more than 200 words. Illuatrationa may not be copied. The abstract should contain conspicuous acknowledgment of where and by whom the paper is presented. Writ6 Publications Manager, SPE, P.O. Box 83383S, Richardson, TX 75083.3836.
Telex, 730989 SPEDAL.

ABSTRACT
Measurement

of return mud flow is the single most

diagnostic indicator of potential well control and lost

circulation
date,

problems

except

flowmeter,

during drilling

for

operations.

electromagnetic

To

Results indicate that the flowmeter

has performed

successfully

conditions

under

adverse

extended

periods

of time

extensive

modification

field
without

the

of the existing

for

need

of

mud flow

system,

induction

which can only be applied for conductive

INTRODUCTION

drilling fluids, it has not been possible to have access

to accurate

measurements

over a wide range of drilling

adverse conditions

It is essential for the safety cf the drilling operation

of return mud flow rate

fluid properties

that any influx

and

below or losses of drilling fluid are detected promptly

such as drilling through gumbo

and recorded accurately.

shale, gas cut mud and other non ideal conditions.

flowmeter
This paper describes

Up to this date, however,

have not been able to accurately record

and

the flow rate of the returning mud. The main reason

field testing of a full bore mass flowmeter based on

for this difficulty is that mud is a dirty, sticky and non-

the measurement

the design, development

of gas or liquid from the formations

of forces generated due to change

in momentum

of the

return

accomplished

by attaching

flow

stream.This

a short

linear-viscous

is

liquid, and measured parameters such

as mud level inside the return pipe, surface velocity

J-shaped

of the mud, drag forces on immersed bodies, etc. are

extension to the return flow line just before the shale

not directly convertible to flow rate over The practical

shaker.

range of mud properties.

This extension

sensors that measure

is instrumented
forces

with force

caused by the flowing

Presently there are two exceptions;

fluid.

electromagnetic
The first generation

prototype has been extensively

ultrasonic

flcwt meter

doppler

meter

one being the

and the second an

2. Two important

tested in the laboratory and in the field over a range

disadvantages

severely

of flow rates up to 1700 GPM and over wide ranges

electromagnetic

flowmeter:

of mud weights.

based mud bev~ me the fluid is non-conductive,

limit

application

of the

it does not work with oil

and

since one of the requirements for correct operation is

a liquid-filled pipe, the return flow line needs to be of
References and illustrations at end of paper

a U- tube shape.
435

DEVEUl?W1 ANDFIEU IW1ING OF A HIOH ACLWWY FULL EIXE RJNUPNklUD~

IADC/SPE I172?B

Also, If the mud is gas cut to a certain extent the

The momentum force created by the fiuid flowing in

electromagnetic

the bend of the pipe, is recorded by a load cell, as

flowmeter

will

give

erroneous

shown

readings.

in fig. 1.

The momentum

force

can be

expressed as shown in equation. (1);

The

newly developed

full bore flow mete~

,which
FM.

works both with water and oil mud, is based on two

measurements:

the liquid level in the return flow line

where

and the velocity of the mud at a fixed distance from

the bottom of the flow line. From these the flow rate is
estimated

assuming

a fked

velocity

profile.

This

meter is therefore subject to possible inaccuracies

the

actuai

velocity

profile

deviates

from

if
the

Klp
=

momentum force

K1

constant

velocity

cross sectional area

In 1983 STATOIL initiated a project aiming towards

recording

and testing

mud

flow

rate,

of a new principle

for

an idea

by

patented

(1)

FM

theoretical flow description.

the evaluation

V2A

= density
=

filled portion of J-pipe

In equation. (1) the liquid mass flow rats may in itself

be expressed as

PETRECO. The principle can be applied to any flow

of either gas, liquid or solids,

and application

return mud flow measurements

requires only minor

modifications

of the fiow line. Preliminary laboratory

tests

1984-85

during

were promising

and it was

decided to build a prototype, test it and instail it on

the semi submersible

ROSS ISLE for further field

tests in the North Sea during 1986-87.

The principle upon which the fiowmeter is based is

the measurement

of forces generated by changes in

the

of the

mud caused

(2)

m which A is the cross section of the J-pipe,

In order

to know the amount of mass (pA%) at any time in the

J-pipe, the degree to which the pipe section is filled
with mud ( A k) must be recorded, This is done by
means of a weight sensor , and the resulting force is

Fw

flowing

VAk

estimated in equation, (3)

DESIGN PRINCIPLE

momentum

to

where

by

changing the direction of flow through a bend in the

K2gp

LAX

acceleration due to gravity

K2

constant

length of J-pipe

(3)

pipe. In the specific case of the return mud flowmeter

the last 6 feet of the flow iine is separated from the
rest by a flexible universal joint. This last part of the
flow line is formed like a J.

The density of the fluid must be known or measured

either with a gamma ray densitometer or with a mud
balance. Because of the low density of the gas in gas
cut mud gas will not cause and error in

the flow

readings if a pressurized density value is fed into the

computer.

The change of velocity in the x-direction,

AVX, depends on the angle of the J and the velocity

itself as shown in fig. 1.
Based on these
built

with

performance

the

principles
objective

information

the first prototype

was

to

and

provide

data

so that the following tasks

could be undertaken:
a)

to build a fuil scale unit to be installed

on a floating drilling rig;

IAIx/SPE 17228

c)

to

11.1:. JOKNSEN,P. 61WIU,

modify

and

mechanical

improve

construction

both

the

and

the

A. I,. IUXO,

G. ISIREVAAG,ANDA. VIGIN

The mechanical design of the J-meter !s very simple,

However, the development

and testir,g has shown

electronic unit of the prototype, in order

that the repeatability and accuracy is grestly aff~cted

to

by some vital details.

achieve

highor

reliability

and

accuracy.
The mounting of the J-meter should in essence be
horizontal, however, slopes of 1-10

FLOWMEIER DESIGN AND OPERATION

degrees will not

alter its accuracy wiih any significance,

The unit described
extensive

here is a version resulting from

tests and ~xperience

iab and the field.

development

gained both in the

The tests

of a completely

have

resulted

in
The first version of the electronic unit was found to be

new electric unit and

unsuited for field use during the preliminary

major changes of the mechanical design.

Any

changes

(universal

joint,

procedure,
A typical
These

J-meter

are the

is composed
load

cells,

of five main parts.

the

flange

end,

reprogrammed;

the

electronics.

The dimension of the

, the universal joint that connects

Two of the blade springs connect the flange

furthe to the J-pipe, The springs are mounted so that

plane

through

two

of

the

blades

and some of

gained from a shallow gas blowout,

It should be possible to receive

least 6 analog iilput signals.

3,

Changes in signal processing should

be carried out via the computer
program.

4.

Continuous
memory is required in
case the electric power on the rig
should fail.

5.

A printer for continuous storing and

dumping of signals is required.

6.

For ease of interpretation the flow

data should also be displayed as
histograms showing the difference
between flow in and out versus time.

7,

A flight recorder function should

store the last 48 hrs of data and
automatically dump the last 1/2 hours
of flow rate data to a printer in case of
alarms.

is

their wiring, and also extends the base of the load

cells to the flange end. The cover is connected to the
flange end with three bolts.
Two forces are recorded by strain gage load cells
of O - 500

N (1 12.4 Ibf) for the

momentum force and O -2000

weight,

manual

2,

The steel cover protects the J-pipe, the load cells and

a range

many

be

operational
be carried

type
out
at

to ihe direction of each of the forces;

gravity and momentum force.

with

too

to

All changes
of
should
possibly
through software.

end with the ring, and the other two connect the ring

perpendicular

a calibration

software

1.

springs ,a flexible seal and a universal link or chain

each

besides,

after

package were identified.

the J-pipe with the flange end consists of four blade

ring.

the

tests.

hardware

some important design principles for the electronic

ROSS ISLE drilling rig.

fig. 3

cells)

Based on this experience

the experience

J-pipe is 12 ID, which matches the flow line on the

As shown in

load

required

of the

operations were necessary during adjustments in the

universal joint with flexible seal, the cover and finally

the J-pipe as shown in fig. 2.

or adjustments

N (449.6 Ibf) for the

This enables the measurement

flow rate of approximately

of a water

5000 l/rein (1321 GPM),

and for mud of density 2.0 kg/1 \l 6.7 PPG) a flow rate
of 2500 I/rein (660 GPM).

Since the sensors should

An overview of the electronic system is shown in

not be exposed to excessive forces the instrument is

fig.

4. The load cells, filters and amplifiers are standard

equipped with over-load safety bolts which block the

equipment

J-pipe when the full scale force is reached.

(Bofors Electrortik).

The load cells are

connected to the amplifiers via a six conductor cable

protected with Zener-barriers.
437

Amplifiers and Zener-

DEWUWQ2W ANDFIELD mIWJ

barriers

are mounted

in a separate

explosion

hazard Zone 1.

amplifiers

is 4-20

OF A HIGH AaRWFULLI

box outside

The output

from the

mA, which corresponds

XXIEBEIURNl~

The Operation

ItW/SPE

menu lists the operations

that the

user most commonly undertakes:

to the

set time constant

lowest and highest forcg on each of the two load

cells. The two signals are collected by the computer

set alarm

AWACS (Analog Warning And Control System).

set alarm delay

The front and back panel of the computer are shown

print

in

stop print

fig. 5.

terminals

On the back panel several

are seen.

multi-pin

AWACS receives the signals

from the load cells, the densitometer

and the pump

flowmeter and converts them to digital values.

AWACS

is designed

easily be expanded

in a modular

The

form and may

to other purposes

by building

The giet time co -

may be chosen as a vaha

t,etween 1 and 100 seconds and indicates the time

period over which the signal representing
difference

should

be averaged.

the flow

If the difference

or just plugging

between the return flow and the pump rate is larger

more external units to it as indicated in fig. 4 and fig.

than the aiarm Iim& then the alarm activates after a

more modules
5.

into the computer

The AWACS

back-up

battery

is equipped
package

with a long lusting

in order to maintain

its

preset delay.

The alarm

cause a {emporary

continuous memory,

de! ~

changing the pump rate.

is important

when

This change will normally

large difference between flow in

and out, and without the delay the alarm would be

When the AWACS

is turned

on the main menu

triggered unnecessarily.

appears, displaying the following sub menus:

All data concerning

Alarm reset

flow in and out of the well over

the last 48 hours are logged twice every minute and

Operation menu

stored in the AWACS.

By choosing ~,

Display menu

will be printed out .

If an alarm condition

should

occur, this also causes the flow information

for the

System menu 1

these data

last half an hour to be printed out automatically.

System menu 2
After selecting the Display
It takes about 15 minutes for a new user to become

between

familiar with the use of AWACS,

delta-flow

The same goes for

menu one may choose

four ways of graphically

presenting

the

vs. time histogram.

calibration of the J-meter on location, This is done b:

setting the appropriate constants into AWACS

using

the menus. A menu or a function in the sub menu is

chosen by

moving the cursor with the arrow keys

Using System menu 1 all the constants necessary to

calibrate

the pump rate and the fluid

density are set. Through !he sub menu, Autozerow,

the

and pressing ENTER when appropriate.

the J-meter,

load

cells

on

the

J-meter

are

zeroed

automatically.
&j

choosing

Alarm reset all the alarms are shut Off.

The alarms are activated when a preset difference

between pump rate (flow rate in) and return flow rate
is exceeded.

Via the relay outputs, different alarms

may be selected

such as horns or flashing

The word ALARM is simultaneously displayed.

lights.

in System

menu 2 it is possible to choose between

two serial or parallel type printers, to set the time and

to display

the four analog signals

histogram

presentation

overlaying

of delta flow.

The latter

function is very handy when ~hecking the functioning

of sensors

and electrical

connations,

drift

variations, and also for adjusting the J-meter.

the

and

17228

H,K. JUI!NWX, P. SKAWE, A,L. FQDXOi G, WJW3Wf3, ANDA. YI.Cj~

IADc/WE 17228.

TESTING OF THE J=ME1ER

However, since this caused no changes in the flow,
In order to test the J-meter after proving the feasibility

the J-meter

of the.concept, it was decided to put it out in the field

personnel again visited the rig. The technical side of

as early

the problem was quickly solved by changing the link,

as possible,

in this

gearing

environment,

and gaining general field experience.

tests during

the tough

the

quickly

To make prelimina~

towards

way

development

offshore

tests of the prototype and later

the progress

of the instrument,

and

the

was just

left alone

administrative

side

until

was

PETRECO

sohmd

after

ir,volving the mud logging company on board Ross

Isle in the evaluation study.

two

laboratory flow loops were built one of which, in fact,

was a full scale copy of the return flow line on ROSS
ISLE.

Calibration

and testing:

After field installation of the

J-meter the next task was to accurately calibrate the

ins~ument,

Initial measurements

on the rig gave

results that were not of the same quality as those

observed in the lab. The inaccuracy was found to be

flow ~

caused by the different

flow path and liquid fill-up

A sketch of the flow loop is shown in fig, 6. The mud

inside the J-pipe compared to when installed in the

pump is a centrifugal pump with a maximum flow rate

laboratory

The flow characteristics

flow loop.

will

of 6434 l/rein (1700 GPM) at 2 bar (30 psi).

To

vary slightly as a function of slope of the flow line,

control

type of bend, the number of branches,

the

electromagnetic

function

of

the

J-meter

flowmeter working on a filled section

The slope difference

of the pipe was used. Variations in the returning flow

installation

rate sometimes

cause

simulated

occurring

by regulating

on a floating

rig were

the pump flow rate with a

computer controlled air operated butterfly valve.

injecting

batches

of compressed

By

air into the loop

ahead of the surge tank it was possible to simulate

valves etc.

between the rig and the lab

of only a few degrees was sufficient to

different

results.

This caused

no futther

problems as the flow rate could easily be calibrated

against the mud pump and/or an electromagnetic
flowmeter on the stand pipe. The field installation
shown schematically

is

in fig. 7.

gas bubbles migrating through the mud and pushing

Due to rig motions

out large volumes of mud down the flowline.

and the absence of filtering of the

raw signal from the load cells prior to the calibration,

The laboratory tests were performed with flow rates
from O to 6434 l/rein (O to 1700 GPM), and with mud
weights from 1.0 to 1.5 kg/1 ( 8.5 to 12.5 PPG).

it was a time consuming process to adjust the zero

values of the transducers.

The

gave valuable

Iaboratoty tests showed that the J-meter measured

generation

the flow rate with an absolute accuracy of:: 50 l/rein

Hence, this operation

input to the design

AWACS

which

of the second

includes

the

filtering

capability.

(13.2 GPM) over the whole range of flow rates. This

is of the order of

After calibrating the J-meter it was tested for a variety

A 1 %.

of flow rates, and

I?~

ard

The rig: The first prototype J-meter was installed on

the semisubmersible

during the next

ROSS ISLE in 1985. However,

Variation

In the beginning of the

Mechanical

led to

breakdown

of the

section

of

fig.

9.

a stable

fig. 10,
Here it is

~will

suppress

high frequency

variations.

alarms caused by these

In

fig, 77

a similar

comparison as in fig. 8 is made for the paddle type

failures, such as a broken link between J-pipe and

cell

) is interpreted in

flow lag time through the well and the flow line. Sf#l

because no person on board the rig was assigned to

load

(fig. 9

indicated that the main r~ason for delta flow is the

first test period practical problems were encountered

the J-meter.

J-meter are

in flow out of the well during

which is an enlarged

of the return flow line was slightly altered to allow far

the job of maintaining

typical readings from the

drilling period

operated using an off the shelf PC. The last section

the extra curve in the J-pipe.

fig. 9

fig. 8

shown and compared to the mud flow into the well.

because of problems with the AWACS it was then

the

rrud weights

months with both oil and water based muds. In

return fIowmeter.

meter.
439

Given

the

equipment,

crews

typical

skepticism

to

new

of gumbo clay was being produced and accumulated

two different tests were performed to test

the metets sensitivity and accuracy.

on top of the shale shakers to such an extent that the

During the first

flow also went backwards and in between the cover

test the pump speed was increased by an unknown

and J-pipe. This was not cleaned properly at first and

number of SPMS,

the flowmeter showed erroneous flow values.

The object of the test was to

determine the pump speed by means of the J-meter.

Based on the J-meter return flow and the volume per

Problems

stroke, the pump speed was calculated

periods with heave, pitch ( 1.5 degree ) and roll, the

to be 224

Related to Offshore

instantaneous

SPM. Readings on the drill floor showed 226 SPM.

significantly

flow

Operations:

rate was observed

During
to vary

since the flowline axis is perpendicular

The second test was performed after simultaneously

to the rigs longitudinal axis.

starting two stop watches, one

of the average flow rate was unaffected due to the

on the drill floor the

other in the mud logging unit. The pump speed was

However, the accuracy

use of filtering and averaging of the raw signal,

!O be changed at some unknown time from 112 SPM

to 114SPM,

This change

was detected

Summary:

by the J-

found

meter down in the mud logging unit 2 min and 17 s

After almost two years of field testing was

that

the

after time zero. The actual change had taken place at

necessary

to

1 min and 40 seconds.

especially

with

Considering

the small flow

was

seconds,

filtered

this

with

behavior

a time
was

constant

found

of 30

problems:

bent.

After having made a new link

The
load
standardized,
maintenance.

4.

Better over-load safety system should

be designed.
Stainless
steel
construction
is
increase
necessary
to
the
instruments life and reduce corrosion
related problems.

5.

between the load cell and the pipe from a chain as

well as adjusting the over-load

safety bolts,

tile

instrument,
reduction

3,

The wire connecting the

load cell to the J-pipe broke off and one load ceii was
permanently

the

The J-pipe must be protec?ed against

mud accumulations
on the outside
due to splashing,

had to be subjected to what could be

called severe mistreatment.

better

to

2.
and the flow

line often gets plugged. To clean out the clay, once

the J-meter

respect

The weight of the J-pipe should be

minimized to further reduce sensitivity
to heave, pitch, and roll.

In the Central North Sea,

gumbo shales are often encountered,

implement

were

1,

to be quite

impressive.
Mechanical

modifications

of

mechanical problems.

rate change of only 27 l/rein ( 7 GPM) and that the

signal

following

J-

meter was tested again. Even though the momentum

cells
shouiii
be
resulting
in easier

cell was permanently bent, showing a force of 105 N

These modifications

at zero load, this offset was

zeroed out and the J-

second generation prototype which is currently being

meter was back in operation

after only 30 minutes of

work.

have been implemented

in a

field tested in the North Sea.

The overload safety bolts were then tested by

having a man standing on top of the J-meter.

Further applications:

At one time the J-meter showed gradually increasing

Other

potential

applications

flow rate, caused by a slow build up of dried mud on

besides detecting volumetric

the outside

system,

of the J-pipe.

This problem

has now

include

keeping

for the
instabilities

track

flowmeter,
in the flow

of the mud return

been solved by using an extended cover to protect

volume during a cement job. Volumetric

the J-pipe from splashing mud.

during a normal primary cement job is inadequate

No serious build up

control

since currently the return flow rate is not monitored.

of material has been observed inside the pipe.

It

is difficult to detect if some of the cement slurry is lost

After the modifications,

the J-meter functioned well

even with large amounts

through.

of gumbo

clay coming

At one occasion, however, large quantities

440

due to fracturing of the formation.

This is especially

the case when cementing

With an accurate

liners.

.,
IAW/SPE 172%

ILK. JQHNWN, p. WWJll

N+

flowmeter on the return line, the quality of the cgment

W!!?,

G* &UWY&lG, WA.

YWN

REFERENCES

job could be better evaluated.

10
CONCLUSIONS
A new flowmeter

for measuring and recording

return mud in an atmospheric

developed.

Speers, J.M. and Gehrig, G, F,: Delta flow:

An accurate,

The existing

system for detecting

kicks and loss of circulation

the

during drilling,

SPE/lADC 13496 (1985).

flow line has been

flowmeter

reliable

is now of an

2,

Orban, J, J,, Zanner,

K,J. and Orbart, A, E.:

industrially acceptable standard and can be installed

New flowmeter

for kick and loss detection

on existing

during drilling,

SPE 16665 (Dallas,

mud return flowlines

modifications.

with only minor

Extended field tests have proven the

1987).

meter to be adequately rugged and easy to maintain.

The

overall

accuracy
k 1

approximately

confirm

flowmeter

is

of the full range flow rate, the

for

mud weights in

1.0 and 1.5 kg/1 (8.5 and

between

12.5 PPG).

the

1700 GPM.

full range being

the range

?40

of

This accuracy,

on a platform

however,

where

is hard to

the reference

flow

readings in some cases are of uncertain quality.

Field tests

have shown

that ?he instrument

has

adequate sensitivity to detect small changes in return

mud flow associated

with normal drilling operaticms

such as making connections

and reciprocating

pipe as well as small variations

d:l

due to changes

pumping speed.
After

field

calibration,

the

instrument

readings

compare favorably with measurements obtained from

electromagnetic

flowmeter installed at the standpipe.

Signal filtering and averaging has proven effective in

reducing

the sensitivity

of the

meter

to vessel

motions.

ACKNOWLEDGEMENT
The Authors
supporting

express

this

their gratitude to STATOIL for

research

and for

permission

to

publish this information.

441

Sept.

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14

15

AFLOWM.

Ie

IN

17

TIME (HRS)

,MmN@n@mllilnud
FhI.s-CQM@WIOFK@fiW~(
WHY
bcl circvmlOm

to

nLw10ut@fn91u)wlwl
nt13-1.

18

. .,

SE 17228
4

1.5f,o 0.5 -

J - meter
(flow

0.0-

out)

1.51.2-

0.90.60,3 _
0.0
0
0

0
0

m
..

TIME (HRS)

Flo. 9-~y@cd

tlow rocwdl~

by tltolna

rlow mtu)

(~

Of HW

dwlng

.hlOtW
on

bald

HOS2 12LE,com~cd

with tha PUMPfbW tic

9tabk dtllllllg pwkwr.

PUMP SiiurOFF
luMhuNGDOWN
OF ONE
VOLUME

Flow in (ol,~.)
3

DR3LL PIPE, 0,11 m3

2

--

W02JT

FLow

r
d

=0.35m dn

0
0

590xd

20

40

80

ao

\
VOIm dunge= 1/2 35 0,35 n 0,1@5m

Flow WI (p3ddle)

2
MAK3NG CONNECTION
1
Cm+ WITIi ONS JOINT BEFORE
CONNECTING KELLY
0b
o

20

40

60

80

100

ST,\R , PUMP
3
\~

- out

~.

t
INCREASING

TIME

Fig. 10-Enlm-gad portion of J+ootw tlow, hkon trom

Fig. 0 at
pproxlmtely t2:20 hours.

- ~

444

t 00