NO20210559A1

NO20210559A1 -

Info

Publication number: NO20210559A1
Application number: NO20210559A
Authority: NO
Priority date: 2021-05-04
Filing date: 2021-05-04
Publication date: 2022-11-07

Description

SYSTEM FOR AUTOMATED REAL-TIME FLUID MONITORING

Field of the invention

The present invention relates to the automated monitoring of industrial and manufactured fluids where those fluids must have defined and controlled characteristics. For the purposes of this description, drilling fluids, more commonly called MUD have been exemplified. The control of MUD characteristics is very diverse and can be applied universally for all industrial and manufactured fluids. MUD as used for the drilling of wells for exploration or production of petroleum fluids have complex blends of water, oil, and solids as well as varying densities and viscosities, to note the primary characteristics.

Background of the invention and prior art

Drilling of wells for exploration or production of petroleum fluids like oil, condensate and gas is very expensive, particularly offshore where the day rate of a drilling unit by far can exceed 500 000 USD.

In the process of drilling, MUD is essential to control the pressure of the well, provide lubrication and cooling, and for transport of drilled out material, often called cuttings. Different MUDs are needed for different conditions, depending on several factors, resulting in MUD of specific properties for specific conditions. The best-known parameters characterizing MUD are density and viscosity. The MUD can be based on water, or mineral oil or hydrocarbon oil and can include traditional materials like bentonite clays, other natural materials, or synthetic materials. For the drilling of wells, the MUD engineer is responsible for the MUD selection and formulation. For other industries, this responsibility could be allocated to another competent person with another title. For the purposes of this claim this person is identified as the MUD engineer.

It is industry practice to monitor the MUD returning from the well, to detect traces of hydrocarbons, particularly traces of gas, which can give an early warning of a gas kick (unintended influx of reservoir fluids into the wellbore).

However, with respect to the MUD to be pumped down into the well by the MUD pumps, it is industry practice to take and manual batch samples to ensure that the MUD properties are as intended. The sample must typically be analysed in a MUD laboratory, either on the drilling rig or on land at a remote location, and the process of analysing may take considerable time. For drilling operations offshore, time is very expensive, and even a moderate reduction in wasted time can have a significant impact on the economy of the operation. Another aspect is the increased safety if it could always be ensured that only MUD having the correct properties is pumped down the drill string.

Many technologies exist for data acquisition and processing of data. Many technologies exist for collecting samples of MUD coming up from the well, and some for collecting samples of MUD as mixed in the MUD pit and ready to be pumped down the drill string. In addition, many technologies exist for analysing single parameters of the MUD.

Some related technology is described in the patent publications CN 201802388, GB 2445209, CA 2005195, MX 2011006044 and US 6378628.

However, a demand still exists for technology in order provide one or more of the following progresses: reduce the time spent for monitoring the MUD properties; provide a continuous monitoring; provide data for more parameters than current industry standard practice; allow elimination of a specific MUD laboratory on the rig; reduce the risk of pumping incorrect MUD composition; reduce waste, tankage requirement and ineffective drilling unit time and increase safety. The objective of the present invention is to meet the demand.

Summary of the invention

The invention meets the demand by providing a system for real-time, automated industrial fluid analysis and monitoring, preferably inline and in real-time in an industrial fluid process including non-Newtonian fluids, such as MUD, dairy products, paint etc. The system is distinguished in that it comprises:

a combined flow rate and density meter measuring fluid weight/density in a range of at least 500-3000 kg/m<3 >or a separate density and flow rate meter

a rheometer that measures rheology in a range of at least 0-450 Pa at a plurality of specific flow rates, wherein each specific flow rate is related to one specific pump speed as related to rpm-rotations per minute, or strokes per minute of a pump, preferably as a parameter correlating to shear rate of the fluid, as correlated to said rpm or strokes per minute,

an arrangement of the instrumentation for measuring parameters as defined above, coupled in real-time to an industrial circulation system of the fluid that is analysed and monitored,

a pump that is controlled for effecting specific rpm or strokes per minute and/or flow rates as prescribed for the measurements,

at least two flow loop legs, oriented horizontal, in a working position, when measuring rheology and viscosity and preferably one flow loop leg adjustable to be oriented in substance 90° apart oriented vertically to measure density, coupled with data from inclinometers allowing compensation or elimination of dynamic impact on the measurements caused by motions of the drilling rig, and allowing using inline instruments,

wherein said instruments are connected in real-time to a data collection and analysis system interface for delivering collected data and analysis to a fluids responsible (MUD for this description) engineer.

Preferably, the density meter and flow rate meter is a combined meter. Additionally, differential pressure is preferably measured in the flow loop leg oriented vertical in working position to measure density, to allow independent operation and measurements, for increased redundancy and increased data quality.

In many preferable embodiments, the invention relates to a system for automated realtime monitoring of the properties of the drilling fluid; more commonly called MUD, to be pumped into the well for pressure control, lubrication, and hole cleaning. Also, where selected, the system comprises an additional system part for real-time monitoring of the properties of the MUD returning out of the well. The system of the invention can significantly reduce the need for and eventually replace and eliminate the traditional MUD laboratory on the drilling rig. In addition, there are reasons to believe that the realtime measurements of MUD parameters by the system are more realistic and more precise than the batch methods traditionally used in the MUD laboratory. The result can be increased rate of penetration by the drilling combined with increased safety.

The system of the invention preferably is comprising one or more of the instruments or functions as follows, in any automated combination, for measuring:

• Pressure: 100 mbar- to full flowing pressure

• Temperature: -5 to 200 °C

• Density kg/m<3>

• Rheology: 0-450 Pa measured at equivalent, Fann 35 rotation speeds (ref API Specification RP 13B).3, 6, 30, 60, 100, 200, 300 and 600 rpm, or other predetermined rheology

• Shear rate s<~1>

• Plastic Viscosity: PV cP

• Yield point: YP Pa

• Gel strength, pa, at 10 seconds, 10 minutes, or other defined interval Other preferable measurements in any combination such as

• pH 0-14

• Emulsion stability Volts

• Oil/water: ratio 0-100 %

• solids and liquids breakdown: 0-100%

• hardness/conductivity 5 pS/cm-2000 mS/cm

• sand content/particle size analysis 0.7 micron-4.8 mm %

• API fluid loss ml/30 min

• Filter cake mm

• Calcium and Magnesium content mg/I

• Chloride content mg/I

• Potassium content mg/I

• Alkalinity (lime content)

• MBT: Methylene Blue Test (clay content) kg/m<3>

• HTHP (High Pressure High Temperature) filter; and

Preferably, the system is configured for operation in hazardous areas with risk for explosions. Alternatively, the system can be arranged in an area classified as safe for the risk of explosions.

Preferably, the interface of the system in real-time to the MUD engineer is to a control room located on the rig, or other position offshore or onshore.

Optionally, a recommendation for action is generated by the system, if selectable threshold values of selectable parameters are exceeded, based on analysis of collected and processed data, and the recommendation is presented to the MUD engineer

The pressure class of the sensors or instrumentation must be compatible with the MUD pressure from the MUD pump for systems installed on the delivery side of said pump.

The real-time interface to the MUD engineer preferably comprises a display visualizing the measured MUD properties. The system is also connected to a database including MUD properties and well property data, empirical and theoretical, and the system comprises real-time connection to the instrumentation arranged operatively to the MUD flow. The system preferably comprises or is coupled to analysis algorithms, for using real-time quality data of properties of MUD to be pumped down the well and preferably also real-time quality data on MUD return flow properties, including comparison of pumped in MUD properties with returned MUD properties, for generating estimates and proposals for future action, such as manual or automated mixing or adjustment of MUD components or parameters based on the estimates or proposals based on the measurement findings.

In some preferable embodiments, the system and/or method of the invention includes one or more of the features or steps as follows, in any combination:

An in-line flow rate meter on the inlet side to the operative rig MUD pump, coupled in real time to the system, for correlating MUD pump shear and flow rate with system pump shear rate and flow rate and for finding any malfunction between MUD pump strokes per minute and flow rate provided and/or shear rate provided (e.g. malfunction of one of the strokes);

A heating element, for controllable heating of the MUD to cover the selectable range of in-well MUD temperatures, for providing closer to actual data on the temperature dependent parameters viscosity and rheology;

Preferably flow loop legs of length at or below 12m, 10m, 8m, 6m, 4m, 3m or 2m or 1,5 m, each comprising at least one differential pressure meter and a mass or volume flow meter, the two flow loop legs oriented horizontal when in working position are preferably adjustable to be oriented 90° apart;

The invention also provides use of the system of the invention, for real-time MUD monitoring of the MUD being pumped into the well, for increased well control, and/or increased safety and/or for increased rate of penetration.

FIGURES

Figure 1 illustrates the system of the invention as related to drilling wells.

Figure 2 illustrates an embodiment of a system of the invention.

Figure 3 illustrates the piping arrangement of the system of Figure 2.

Figure 4 illustrates the system of Figure 2 in a working position.

Figure 5 illustrates the piping arrangement of the system of Figure 2 in a working position.

Figure 6 illustrates a further embodiment of a system of the invention, in a working position.

Figure 7 illustrates the piping arrangement of the system of Figure 6, in a working position.

Figure 8 illustrates a further embodiment of a system of the invention, in a working position.

Figure 9 illustrates the piping arrangement of the system of Figure 8, in a working position.

Detailed description

We refer to Figure 1 : The system, as presented in relating to use in drilling of wells, preferably is comprising an inlet for MUD flowing to the instruments for parameter measurements in the system, and an outlet for returning the MUD. Two systems are presented wherein: one is for a system monitoring MUD flowing into the well, the inlet is coupled to the manifolded flowline connecting to the MUD pump inlet line, the MUD pit, or an accessible point of specific interest. A second system is for monitoring MUD flowing out from the well; the inlet is coupled to the MUD return line in the MUD treatment system after extraction of the cuttings, at an accessible point of specific interest. Typically, the outlet for MUD from the system of the invention is arrange at a short distance downstream to the inlet, with respect to the MUD circulation system on the rig for circulating MUD through the well.

The system is connected to a data system for logging and preferably, measurements are compared and analysed, including preferably to compare MUD data/parameters for the MUD being pumped into the well with MUD data/parameters for the MUD returning from the well, for providing direct indications on well control.

Reference is made to Figure 2, illustrating an embodiment of a system of the invention. The system of the invention is also termed a RheoSense unit. The embodiment of the invention comprises a metal framed piping skid 1 and a metal framed electrical skid 2 comprising a HMI panel 2.1 and an emergency stop 2.2 electrical cabinet 2.3 and a piping system 3.

The arrangement of the piping system 3 of the system 1 of the invention is illustrated in detail in Figure 3.

Figure 2 and Figure 3 illustrate the system 1 and piping arrangement of the invention in a closed, non-operating or non-working position. Figure 4 illustrates the system of Figure 1 in a working position. Figure 5 illustrates the piping arrangement 3 of the system of Figure 2 in a working position.

As clearly visible from the figures, when the system of the invention is in working position: figures 4 and 5, the piping arrangement 3 thereof is arranged otherwise than in non-working position: Figures 2 and 4.

With reference to figures 3 and 5, Identical equipment items are numbered with identical reference numerals.

The piping arrangement 3 further comprises a flushing nozzle 3.1, a ball valve 3.2, an inlet 3.3, an outlet 3.4, a DP housing 3.5, a positive displacement pump 3.6, a mass flow meter 3.7 and/or alternatively a volume flow meter, a pressure transmitter 3.8, a differential pressure transmitter 3.9, an inclinometer enclosure 3.10 and a rupture disc 3.11.

Figure 6 shows an alternative embodiment of the invention where the system is mounted on a base sub-frame which can be separated into 3 parts: identified as 1 ,2 &3. Item 4 refers to the piping system which is further detail in figure 7 where Identical equipment items are numbered with identical reference numerals as figures 3 & 5. In this system configuration, the electrical equipment, identified as items 2.1 HMI and 2.3 Electrical box in figures 2 and 4 are not shown as they would be installed remotely in an area classified as safe for the risk of explosions

A third embodiment of the invention is presented in figure 8, where two systems are installed within a purposefully sized container for transportation, storage, and protection. This dual system allows for measurement of MUD flowing into and returning out of the well. Such a compact solution when drilling of wells, suits situations where the MUD storage and pumping into the well is located close to MUD treatment out of the well. Figure 9 shows the piping configuration; identified as item 3 in figure 8 of one system, on one side of the container. The system on the opposite side of the container is effectively a mirror copy of this piping configuration. Identical equipment items are numbered with identical reference numerals as figures 3 & 5. The system of the invention can replace and eliminate many of the traditional functions performed in the MUD laboratory on the drilling rig. Thereby, laborious, and time-consuming batch sampling and laboratory analysis can be avoided. Measurement signals are preferably transmitted directly to the MUD engineer and/or control room, as edge computed results or raw or filtered signals, or combinations.

The special arrangement of the system and method of the invention, with the presented piping configurations utilising differential pressure measurements and mass flow measurements and/or volumetric flow measurements and/or density measurement in each flow loop leg, and each flow loop leg coupled to the pump for controlled MUD flow rate, allows density, viscosity and rheology measurements with said simple inline instruments, since the parameters actually measured are linked to each of density, viscosity and rheology.

The specific construction of the system provides measurement of density, viscosity, rheology and numerous other MUD parameters as required and preferable. The pump of the system is used to measure rheology at specific shear rates, as related to specific pump rotations per minute, rpm, or strokes per minute. This provides data that can fit far better into models for numerical simulation of the drilling process, since the data are much more realistic and correct compared to traditional measurements.

The system of the invention is also termed a RheoSense unit or -skid since the data on rheology is particularly valuable for effective and safe drilling. Rheology is the dependence of viscosity as function of shear, as found in non-Newtonian fluids. By varying the pump speed and measuring at specific speed corresponding to specific flow rates or flow within the well and circulation path, more representative data can be provided, compared to traditional batch sample measurements. The MUD can be taken from the MUD pump outlet line, measuring pressurized fluid as being pumped into the well, the MUD pump inlet line, the MUD return line, the MUD pit, or in any point of specific interest accessible. Measurements can be compared and analysed. For example, comparing MUD data/parameters for the MUD being pumped into the well with MUD data/parameters for the MUD returning from the well, give direct indications on well control, as the person skilled in this art may understand, this also allows automated mixing or adjustment of MUD properties.

The progress provided by the system of the invention is increased rate of drilling penetration, ROP, combined with increased safety and health, and reduced risk for spill or leakage of hydrocarbon components.

Some further advantages of the present invention are as follows:

1. Interface otherwise known technology into the existing MUD process. The skid mounted system of the invention can easily be retrofitted to existing MUD systems or installed in new MUD systems.

2. Gain MUD properties automatically from the MUD process. Reduce time and uncertainty by using a standardized automated system with continuous measurements, which is not available to the industry today.

3. Deliver real-time MUD properties data from one unit from the MUD system overall or for specific data, directly to a user (software or person) from the installed set of instruments and processing software.

Some key features:

• The arrangement of the measurement instruments, (some instrument can be located remotely), allows continues flow of MUD.

• Allow variable flow of MUD through the skid to optimize measurements

• Allow automated batch measurements in parallel to the continuous flow allowing measurements in “still standing fluid"

• Generation of MUD reports and trends of parameters provided to a given software interface, or directly displayed on the skid

• Combination of measurements taken by one “unit”

• Ex certified for function in potentially explosive atmospheres

· Fit to existing installations, can be installed off-line main process

• Batch and/or inline real-time measuring for feasible parameters like gel and rheology parameters, is one of the key benefits. The MUD is routed through the skid, through flow loop legs and then provide each instrument with optimal conditions for measuring, giving better and more precise readings. Reduced data treatment afterwards.

No other automated technology than the technology of the invention can better ensure the drilling fluid or MUD being pumped down into the well has correct composition, with correct properties, while achieving such result so fast, simple, and consistently, and do so for long periods without human intervention. Moreover, no other technology is so feasible for retrofitting into existing drilling fluid systems, without significant modifications.

Abbreviations and Nomenclature

Claims

1.

System for real-time, automated industrial fluid analysis and monitoring, preferably inline and in real-time in an industrial fluid process including non-Newtonian fluids, such as MUD, dairy products, paint etc., characterised in that the system comprises:

2.

System according to claim 1 , comprising of an installation in a drilling MUD process with at least one system part installed to analyse and monitor MUD flowing into a borehole or well and preferably one system part installed to analyse and monitor MUD flowing out of a borehole or well.

3.

System according to claim 1 or 2, comprising an inlet for MUD for parameter measurements by the instruments in the system, and an outlet for returning the MUD, wherein the inlet is coupled to one of: the MUD pump outlet line, measuring pressurized MUD as being pumped into the well; the MUD pump inlet line; the MUD return line; the MUD pit, or in any point of specific interest accessible.

4.

System according to claim 2 or 3, wherein measurements are compared and analysed, preferably including to compare MUD data/parameters for the MUD being pumped into the well with MUD data/parameters for the MUD returning from the well, for providing direct indications on well control.

5.

System according to any one of claim 1-4, comprising one or more of the instruments or functions as follows, in any automated combination, for measuring:

• Pressure 100 mbar- to full flowing pressure

• Temperature -5 to 200 °C

• Density kg/m<3>

• Rheology 0-450 Pa measured at equivalent, Fann 35 rotation speeds (ref American Petroleum Institute Specification RP 13B).at 3, 6, 30, 60, 100, 200, 300 and 600 rpm, or other predetermined rheology

• Shear rate s<~1>

• Plastic Viscosity: PV cP

• Yield point: YP pa

• Gel strength, Pa, at 10 seconds, 10 minutes, or other defined interval

• pH 0-14

• Emulsion Stability volts

• Oil/water 0-100 %

• solids and liquids breakdown 0-100%

• hardness/conductivity 5 pS/cm-2000 mS/cm

• sand content/particle size analysis 0.7 micron-4. 8 mm %

• API fluid loss ml/30 min

• Filter cake mm

• Calcium and Magnesium content mg/I

· Chloride content mg/I

• Potassium content mg/I

• Alkalinity (lime content)

• MBT: Methylene Blue Test (clay content) kg/m<3>

• HTHP (High Pressure High Temperature) filter

6.

System according to any one of claim 1-5, wherein the system, or parts thereof, is arranged in a skid, where the embodiment is as presented in figures 2 through 7, safe for operations in hazardous areas with risk for explosions.

7.

System according to any one of claim 1-6, wherein the system, or parts thereof, is arranged in a container as presented in figures 8 and 9, safe for operation in hazardous, areas with risk for explosions and extreme climate conditions.

8.

System according to any one of claim 1-7 where the system is arranged as integrated into the fluid process system in an appropriate configuration.

9.

System according to any one of claim 1-8, wherein the interface in real-time to the MUD engineer is to a control room located on the rig, in other position offshore or onshore.

10.

System according to any one of claim 1-9, wherein a recommendation for action is generated by the system, if a selectable threshold value of a selectable parameter is exceeded, based on analysis of collected and processed data, and the recommendation is presented to the MUD engineer.

11.

Method for increased control of a drilling process, by using the system according to any one of claim 1-10, the method comprising:

configuring at least two flow loop legs in horizontal orientation, in a working position, for measuring rheology and viscosity and preferably one flow loop leg in substance 90° apart oriented vertically to measure density coupled with inclinometers allowing compensation or elimination of dynamic impact on the measurements caused by motions of the drilling rig,

connecting the system to the well MUD circulation system on the rig, and measuring MUD weight/density in a range of at least 500-3000 kg/m<3>'

measuring rheology 0-450 Pa at a plurality of specific flow rates, wherein each specific flow rate is related to one specific pump speed as related to rpm-rotations per minute or strokes per minute, wherein the pump is included in the system and/or is the MUD pump on the rig,

measuring further parameters as intended and as provided instrumentation for, transmitting the measured data in in real-time to the data collection and analysis system for analysis and presentation to a MUD engineer.

12.

Method according to claim 11 , further comprising comparing pumped-in MUD properties with returned-MUD properties for generating estimates and recommendations by the data collection and analysis system, for future actions.

13.

Use of the system according to any one of claim 1 -10 or the method of any one of claim 11-12, for real-time MUD monitoring of the MUD being pumped into the well and/or returning from the well, for increased well control, and/or increased safety and/or for increased rate of penetration.