Automated Mud Skid Holds Promise of Safety, Efficiency Improvements With Real-Time Fluid Monitoring

As industry buzzwords go, “automation” has spent its time in oilfield vernacular climbing the ranks of widely used terms. It now resides as one of the go-to designations for signs of advancement in any number of disciplines. Its use has been tied most frequently with drilling operations as contractors look to keep employees out of harm’s way via a robotic take-over of most motion-intensive jobs on the rig’s drill floor—basically anything that grips, clamps, or spins. More recently, the term has moved away from the drill floor and into other well construction operations allowing for things such as remote, real-time measurements without the need for boots on the ground. For areas like west Texas and the Permian Basin shales, having the option for remote readouts and a component of automation that can allow for corrective actions should the need arise can go a long way in terms of safety and efficiency gains as well as better manpower application. Unsurprisingly, the area has become a solid testing ground for new, expanding efforts in automation. With dreams of new drilling-fluid-monitoring automation, Eric van Oort, a professor at The University of Texas at Austin and former Shell research scientist, and select students came up with a new way to automatically measure mud parameters such as viscosity without the use of a traditional viscometer. “The fact that we still use manual measurements, some of them now 90 years old, is quite puzzling in this day and age,” van Oort said. “The Marsh funnel, for instance, was introduced in the 1930s, and other mud tests go back to the 1950s and 1960s. These API measurements have served us well, but the question is, can you do something more now with modern measurement techniques and sensors? So, I started working on new ways of measuring the viscosity and density, and then later fluid loss and even solids and salinity in muds. That proved to be all very successful and promising.” Construction of a mud skid to house the equipment and sensors needed to conduct these tests in real time was the next step in the evolution of van Oort’s concept. That initial skid was a cannibalized and reworked version of a unit that was employed on Shell’s Rig 1, which the supermajor built for its in-house rig-automation research based in Pennsylvania. This early mud skid, considered the prototype of van Oort’s design, was abandoned before it was properly tested. “We generated quite a bit of IP [intellectual property], my students and I at UT,” he said. “The Shell skid hadn’t seen a significant amount of service, and it had some nice components that we could reuse. We took that skid apart and reconfigured it and put it out in the field with Pioneer Natural Resources for a set of field trials in the Permian. Those went well.” The field trial results were shared in a paper presented at the 2019 Unconventional Resources Technology Conference (URTEC 2019-964). The paper concluded that the pipe viscometer employed by the skid allows for the characterization of additional rheology parameters, which cannot be obtained with Couette-type viscometers, such as the critical Reynolds number, characterizing the transition from laminar into turbulent flow, and the friction factor in the turbulent flow regime.