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

0

1

2

3

4

5

6

7

8

9

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

5

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

0

10

20

30

40

50

60

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

20

40

60

80

100

120

140

160

180

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

100

200

300

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

10

20

30

40

50

60

70

80

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

0 2 4 6 8 10 12 14 16 18 20-100

0

100

200

300

400

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

19

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