SENSOR DEVELOPMENT AND CALIBRATION METHOD · PDF fileMud Circulation System – Basics ......
Transcript of SENSOR DEVELOPMENT AND CALIBRATION METHOD · PDF fileMud Circulation System – Basics ......
SENSOR DEVELOPMENT AND CALIBRATION METHOD FOR INLINE DETECTION OF VISCOSITY AND SOLIDS CONTENT OF NON-NEWTONIAN LIQUIDS
Svetlana Hageraats-Ponomareva (Shell) and Nikola Pelevic (VSL)
1 January 2016
European Metrology project on Non-Newtonian rheology
INTRODUCTION
2
Linear viscosity Water & Oil
Existing metrology
Shear rate dependent viscosity = Rheology of non-Newtonian liquids Blood, paint, soup, juices, shampoo, syrup,
ketchup, toothpaste, ink, and drilling mud
No existing measurement standard & no estimate of uncertainty
Oil well drilling: Recommended practices vs traceable measurement
DRILLING FLUIDS – FUNCTION AND REQUIREMENTS
Mud Circulation System – Basics Typical mud properties - Water based or (synthetic) oil based or cement - Flow: 0 – 2000 L/min, 100-350 bar - Power Law or Bingham Plastic rheology - Density range 0,7 to 2,4 SG (oil to weighted mud) - Additives: salt, bentonite, viscosifier e.g. starch baryte solids ≤ 0,125 mm Base for pH of 10, surfactants, et cetera
• Well Control • Transport cuttings to surface • Suspend solids in annulus • Release solids at surface • Lubricate bit • Provide Power • Stabilize borehole • Enable bore hole logging
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1
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10
0 200 400 600 800 1000 1200
Shea
r st
ress
[Pa]
Rate of strain [1/s]
Shear stress (Newtonian)
Shear stress (non-Newtonian)
Newtonian fluid: viscosity is constant
Viscosity = =
stress required to flow
amount of deformation
Non-Newtonian (Herschel-Bulkley)
n
y k
Newtonian
DRILLING AUTOMATION – WELL HYDRAULICS
5 May 2011
RHEOLOGY THEORY- SIMPLIFIED
Rheology models
• ECD / frictional pressure losses
• Particle carrying capacity / hole cleaning
• Frictional forces / hookload, torque and drag
6 May 2011
MAIN INFLUENCES OF DRILLING MUD RHEOLOGICAL PROPERTIES
How to measure viscosity
on a drilling location
0 200 400 600 800 1000 1200 1400 1600 1800 20000
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10
15
Shear rate [1/s]
Shear
str
ess [
Pa]
Haake measurement series (1/3)
Haake measurement series (2/3)
Haake measurement series (3/3)
Fann measurement series (1/3)
Fann measurement series (2/3)
Fann measurement series (3/3)
Fit through Haake data, y = 2, k = 0.03, n = 0.74
Fit through Fann data, y = 3, k = 0.03, n = 0.81
Shea
r st
ress
[Pa]
Shear rate [1/s]
VISCOSITY MEASUREMENTS
TECHNICAL BACKGROUND – FANN 35 (FIELD EQ)
8 January 2014
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0 100 200 300 400 500 600
Shea
r St
ress
, q (1
O =
1.0
65 lb
s/10
0ft2
=
0.51
1 Pa
)
Shear Rate, RPM (1 RPM = 1.7023 sec-1)
Oil field equipment: Fann 35 – poor prediction of the yield stress
RPM Defl. 600 58 300 44 200 38 100 31 6 17 3 15
Derived Data
AV = q600 /2 =29 cP
PV = q600 – q300 =14 cP
YP = q300 – PV = 30 lb/100ft2
9 May 2011
AUTOMATED RHEOLOGY MEASUREMENT APPLICATIONS
Automatic continuous rheology measurements of drilling fluid in process of drilling a well
Improved / automated management of drilling fluid properties
Continuously updated process models
Apply continuously updated models in
Prediction and diagnostics of downhole state
Automated control of drilling sequences
ILLUSTRATION OF OBJECTIVE
New rheometers but no benchmarking on uncertainty:
1. Halliburton paper on HPHT viscometer for cement slurries
2. Down hole rheometer of University of Texas & Baker Hughes
3. MRI-based rheometry
Examples from SPE Drilling conference in London, March 2015
INTRODUCTION ENG 59 NNL
January 2016 11
ENG59 - NNL
Sensor development and calibration method for inline detection of viscosity, density and solids content of non-Newtonian fluids
OBJECTIVES ENG59NNL PROJECT
Objectives • Develop measurement standards and reference materials • Determine physical properties of non-Newtonian liquids • Develop inline sensors including on-site calibration methods
Scientific & technical excellence • Resolve fundamental issues: wall slip, solids content, transient flow • Continuous measurement solutions including on-site calibration • Develop non-Newtonian metrology
SELECTION OF CRM
CRM
Environment
Cleaning
Technology Large production
Manufacturing
Main requirements
Cover domain of drilling fluids
Easy to produce (recipe)
Stable (time / pressure / temperature)
Here examples of fluids haracterisitics of potential reference fluid
Yield point determination
POLYMER BASED CRM
14 May 2011
polystyrene-polyisoprene copolymer polystyrene-block-polyisoprene-block-polystyrene full recipes and mixing procedures are available at
http://www.eng59-rheology.eu/
Preliminary results are available
NNRL1 - NEWTONIAN OIL
0 500 1000 1500 2000 2500 30000
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200Shear stress / Pa as function of Shear rate / (1/s) for all participants (-Inf < Shear rate / (1/s) < Inf)
Shear rate / (1/s)
Shear
str
ess /
Pa
IRIS_NNRL1
METAS_NNRL1_CSR
METAS_NNRL1_CSS
PTB_NNRL1
Shell_NNRL1
VSL_NNRL1_CR
VSL_NNRL1_CS
NNRL2
-100 0 100 200 300 400 500 600 7000
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400
500
600
700Shear stress / Pa as function of Shear rate / (1/s) for all participants (-Inf < Shear rate / (1/s) < Inf)
Shear rate / (1/s)
Shear
str
ess /
Pa
IRIS_NNRL2
METAS_NNRL2_CSR
METAS_NNRL2_CSS
PTB_NNRL4
Shell_NNRL2_cone1
Shell_NNRL2_cone2
VSL_NNRL2_CR
VSL_NNRL2_CS
unloading
NNRL3
-200 0 200 400 600 800 1000 1200 14000
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90
100Shear stress / Pa as function of Shear rate / (1/s) for all participants (-Inf < Shear rate / (1/s) < Inf)
Shear rate / (1/s)
Shear
str
ess /
Pa
IRIS_NNRL3
METAS_NNRL3_CSR
METAS_NNRL3_CSS
PTB_NNRL3
Shell_NNRL3
VSL_NNRL3_CR
VSL_NNRL3_CS
unloading
NNRL4
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500
600
700Shear stress / Pa as function of Shear rate / (1/s) for all participants (0 < Shear rate / (1/s) < 20)
Shear rate / (1/s)
Shear
str
ess /
Pa
IRIS_NNRL4
METAS_NNRL4_CSR
METAS_NNRL4_CSS
PTB_NNRL2
Shell_NNRL4
VSL_NNRL4_CR
VSL_NNRL4_CS
unloading
ACHIEVEMENTS: 5 DIFFERENT RHEOMETRY METHODS
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1. Robotized bob-and-cup 2. Spindle-in-tube based 3. Linear Coriolis 4. Ultra sonics based 5. MRI-based rheometry
Discussions with 10 vendors on IRIS rig testing Additional: - Covering other physical properties - Complementary!
VISCOSITY AS A FUNCTION OF SHEAR RATE
20 May 2011
Combined MRI and USD
NEXT STEPS
• Testing and validation of sensors in operational environment Q3-Q4 2016 (at Ullrig facility)
• Apply calibration method to commercial in-line/at-line rheometer solutions currently available
• Publishing of standard reference fluids and calibration methods 2017
• Establish fluids and calibration methods as standards
• Work towards establishing industry standard for Non-newtonian rheology measuerements
SUMMARY
Objective The metrology standard for the rheometry of non-Newtonian liquids is to lead to industrial standards that replace recommended operational practices by traceable measurement methods in combination with practical calibration methods. Progress To date the project has progressed strongly on 1. the development of Standard Reference Liquid and combination with recipe for
operational bulk volumes 2. the calibration method 3. selection of realistic inline and at line industrial rheometry solutions. Opportunity and Challenge 1. Opportunity for the development of the metrology standard in the physical
variety of rheometry solutions. 2. Challenge: Variation in measurement techniques requires diversity in expertise
in integrated operational measurement systems.
ACKNOWLEDGEMENTS
23 May 2011
The authors would like to acknowledge the coordinator and members of the ENG59 NNL Joint Research Project of the European Metrology Research Programme (EMRP). The EMRP is jointly funded by the EMRP participating countries within EURAMET and the European Union.
NMIs Sensor manufacturers Oil & gas Research institutes
24 May 2011