Research on Automatic Testing System of Part Mud Properties in Mixing Tank

Research on Automatic Testing System of Part Mud Properties in Mixing Tank

Available online at www.sciencedirect.com ScienceDirect Procedia Engineering 73 (2014) 127 – 133 Geological Engineering Drilling Technology Conferen...

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Available online at www.sciencedirect.com

ScienceDirect Procedia Engineering 73 (2014) 127 – 133

Geological Engineering Drilling Technology Conference (IGEDTC), New International Convention Exposition Center Chengdu Century City on 23rd-25th May 2014

Research on Automatic Testing System of Part Mud Properties in Mixing Tank Wu Xiaominga*, Zhang Fenga, Zhao Mina, Wu Chuana, Yuan Qingsonga a

Faculty of Engineering, China University of Geosciences, Wuhan, 430074, China

Abstract This paper presents a viscous torque sensor, and designs the special assembly with combined pressure gauge that meets the test need and is convenient to put into mud tank or pool. Compile the calculation program of mud performance, and develop the specific sequential circuits. It achieves tests of mud performance parameters rapidly and intelligently, and avoids the test error carried by operations.

© 2014 Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license © 2014 The Authors. Published by Elsevier Ltd. (http://creativecommons.org/licenses/by-nc-nd/3.0/). Selection and peer-review under responsibility of Geological Engineering Drilling Technology. Selection and peer-review under responsibility of Geological Engineering Drilling Technology Key words: Mixing Tank, Mud, Automatic Detection, Parameters

1. Introduction Here The performance of the drilling mud has a great influence on drilling efficiency and drilling safety. However, the situation for the detection and analysis of drilling mud in the drilling site is not satisfied and even poorer, so the mud cannot play their effectiveness and affect the quality, efficiency and safety of drilling engineering. The situation is mainly showed in these areas: 1)the conventional instruments of mud need artificial and complex operations, which causes the measure error is bigger; 2)The mud samples is discontinuous and are obtained in the limited location, and the number of mud samples is relatively scarce, the representative of which is not ideal; 3)the test data rely on manual record and memory capacity is very limited, at the same time the performance of real-time is

1*

Wu Xiaoming, Tel: +86-13907136574. E-mail address: [email protected]

1877-7058 © 2014 Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/3.0/). Selection and peer-review under responsibility of Geological Engineering Drilling Technology doi:10.1016/j.proeng.2014.06.180

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relatively poor; 4)Manual calculation leads to that the uses of conversion formulas are not perfect and causes the analysis indexes of mud performance missing so that the quality of analysis and evaluation about mud is poorer. So it is desirable for many drilling engineering that developing an instrument set to mud tank or mud tool randomly which detects automatically and analyzes the performance parameters of mud without manual operation. It can eliminate the above-described various defects so that this achieves the goals of getting the mud performance parameters at job site fast, accurately and conveniently [1]. Considering that it can both meet the basic needs for mud performance at the field and avoid the complexity of the process, the study only choose two aspects of mud in density and its distribution and mud rheology properties as the parameters of the automatic detection. 2. System Composition This automatic checkout system about mud properties is used for detecting automatically and analyzing some important performances of the drilling mud in agitator tanks or mud pools, including mud density, its distribution uniformity, mud viscosity and rheological parameters. As shown in Fig.1, the basic pressure signal is detected by three pressure sensors, and a stress sensor detects the original torque signal as the result of the viscosity. After these electrical signals enter the MPU through conversion in AD (collecting data automatically), calculating intelligently by the program, we can obtain the density data of mud which distributes along the depth in the tank or pool and the rheological parameters of different flow patterns. The test results are showed in real-time by meters and it records the data automatically [2].

Fig. 1 The Principle Diagram of Signal Process

Fig. 2 Settlement Diagram of Assembly

1-the seal chamber, 2-viscosity detection module, 3-pressure sensor, 4-inside integrated circuit, 5-the seal chamber in bottom, 6-agitator, 7-display screen

As shown in Fig.2, designing and making the cylindrical main assembly, the sensors are installed in it. Three pressure sensors are distributed uniformly in a certain distance along the vertical. The viscous force is combined with the rotating drum driven by diving sealed motor and the inner cylinder, and is detected by the torque sensor according the sequence of program controlling. According to the field situation, the assembly can be placed in the mud tank or pool in any appropriate location, but its overall requires to be submerged in mud under the surface completely. The data of automatic collection, recording, showing, intelligent analysis, sequential controlling and power are integrated on a circuit board, and are packaged in the instrument box. The instrument box is connection with the main assembly by a multi-cable.

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3. The Density and Its Detection Automatically Using the principle of testing fluid pressure by the pressure sensor (part 6 of Fig.2), we distribute 3 pressure sensors along the vertical as the same distance d in the assembly (the distance L between sensor to the bottom of the tank or pool is known), and then measure the mud pressure P1, P2, P3 as the depth. So in the condition of that the mud density distributes unevenly and the height of liquid level is unknown, we can calculate the density parameters according to the following formulas(density distribution ρ˄h˅, the average density ρa, height of liquid level hi) ­dF S ˜ U ˜ g ˜ dh ® ¯ U U 0  kh

(1)

Integral to:

³ S ˜ U  kh ˜ g ˜ dh ³ dF ³ S ˜ U  kh ˜ g ˜ dh ³ S U gdh  ³ Skghdh 0

h

h

0

0

F

SU 0 gh 

h

0

0

h

0

(2)

0

Force: Skgh 2 K 2

(3)

The pressure: P

F S

U 0 gh 

kgh 2  K0 2

(4)

As some special cases of calculation, there are several simple results that have been sorted: 1)If the mud uniform density is ρ, and the height h1 of liquid level is known, so it can be easily gotten:

U

p1 gh1

(5)

2) If the mud uniform density is ρ,but the height h1 of liquid level is unknown, so it can be gotten: h1

p1d p2  p1

(6)

U

p2  p1 gd

(7)

3) Assuming that the mud density changes from top to bottom by ρ=ρ0+ah, and the height h1 of liquid level is known, it can be gotten: a

2( p1h2  p2 h1 ) gh1h2 (h1  h2 )

(8)

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U0

( p2 h12  p1h22 ) gh1h2 (h1  h2 )

Ua

p1h1h2  p1h22  L( p1h2  p2 h1 ) gh1h2 (h1  h2 )

(9)

(10)

4) Assuming that the mud density changes from top to bottom by ρ=ρ0+ah, and the height h1 of liquid level is unknown, it can be gotten:

h1

a

 (3 p1h2  2 p2  p3 )  (3 p1d  2 p2  p3 ) 2  4 p1 (2 p1d 2  4 p2 d  p3 d ) 2 p1 2 p2 2p  1 gd (h1  d ) gd

U0

p1 ah1  2 gh1

UH

U0 

a( L  h1  2d ) 2

(11)

(12)

(13)

(14)

The pressure data that were collected continuously are changed into electric signal, and are transformed into digital sequence by A/D which becomes the input parameters in MPU, and then it can compute intelligently and automatically by pressing the above formulas, at last we can obtain mud density and distribution of quantitative results and the data of the tank or pool level changing in real-time. In addition, the detected pressure is fluctuated because the mud in the tank or pool is often mixed. Therefore, to get the ideal mean curve, we need to make the detected pressure data with special filtering methods. 4. The Automatic Test of Viscosity As shown in Fig.3, using the basic principle of mud viscosity between concentric cylinders by API standard, the external rotation drive mud in annular gap, and pass the mud viscous force to static suspended cylinder, and formats the torque within the cylinder. Then a special stress sensor designed, and it converts the inner cylinder into electricity, then the power is transformed to the digital quantity that MPU can reads through the A/D converter. Writing read, computing and storage procedures[4], and then inserted in the MPU system so that it can detect automatically, record the inner barrel torque, and calculate the mud viscosity by the regulation parameters. The signal transmission between stress sensor and MPU system can be achieved by the communication cables. So we can make the MPU recording, displaying and the controlling part into relative independent unit then hung outside the mud tanks or pools for any positions that are convenient to observe and control, and the components located in the front of stress sensor are submerged in the assembly which is placed in the mud tank or pool. The power drives the rotation cylinder at a high speed and the shaft part must be sealed to make sure that the power part has no water. It adopts the mechanical seal and can resist several water pressures without affecting the axis of rotation so that it can meet the requirements of the scene. The stress senor is made of strain gauge and must apply waterproof glue to prevent the circuit water damage.

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Fig. 3 The Principle of Consistency Test 1-the protecting cylinder 2-external rotation 3-static suspension inner barrel 4-stress senor

Liquid level fluctuation can affect instrument measurement due to the slurry in mixing. As shown in Fig.3 in 1, making the outer cylinder own holes as far as possible to ensure the instrument under the condition of intensity so that the measuring serum can enter the measured part through the pore, at the same time it can resist the influence of serous fluctuations in external rotating and static inner barrel. At last, make sure that the data measured by the stress sensor is stable as far as possible. 5. Computing Rheological SPC Variable Speed and Intelligently To test the rotary viscosity of certain viscous force of mud, inner cylinder torque can be got by changing the speed. Just as the rheological parameters of Newton, Bingham, Power law and Carson, four kinds of typical mud flow patterns (reflecting their respective viscosity), the torque values in Ф 300 and Ф 600 are computed according to their respective conversion in the requirements of specification. Therefore, make the two-stage speed shifting mechanism into the assembly and make the change control program into MPU. To realize infinite speed, adjust the frequency and duty cycle of the control signal through controlled DC motor, so achieve the motor jumping from 300 RPM to 600 RPM without mechanical switch. After the transformation, the actual speed is measured by rotary encoder and feedback to MPU so we can realize the adjustment of the acceleration and deceleration and ensure the accuracy of speed around f0.2. The processors bring computing algorithm. When the viscosity of the slurry and other load index exceed the instrument itself, it sends alarm signal and standby work. It starts again until the mud performance within the normal range. The control principle of speed is shown in Fig. 4.

Fig. 4 The Principle Diagram of Variable Speed

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Wu Xiaoming et al. / Procedia Engineering 73 (2014) 127 – 133

For every basic testing cycle, the working time designed by speed control program for Ф 300 and Ф 600 is 8 seconds in order to make sure read the torque values within the range of its steady. Software program of embedded MPU put the value of Ф 300 and Ф 600 into the following formulas to achieve computing slurry rheological property intelligently. Table. 1 The Summary of Rheological Formulas Apparent viscosity (mPags)

 T  

KD

Absolute viscosity of Newtonian fluid (mPags)

K

Bingham fluid

Plastic viscosity (mPags)

PS

Dynamic shear (Pa)

W

 T   T 

.

T Q

Q

OJ

Power law fluid

Consistency coefficient (Pagsn) Flow pattern index dimensionless

Carson fluid

High shear viscosity (mPags) Carson dynamic shear (Pa)

T 

T   T 

K f 

WF



T  T 



   T   T  T 

^> T







  T 

@`



6. Calibration and Test Data For the calibration of viscosity and density, we will put three parts mud of different viscosity and density to the comparing tests by six-speed rotational viscometer (ZNN-D6), density meter (YM-2) and this instrument. The read values inФ 300 and Ф 600 list in Table. 2. It can be gotten that the accuracy of this instrument is higher, including the maximum deviation rate of viscous reading is only 1.64% and the maximum deviation rate of density is only 1.22%. Do the experiment on density distribution with the mud system that sets faster. Mix dispersant which consists of 400 mesh barite 25%, mud making clay 6% and Na2CO3 0.24% with mention of adhesive that consists of XC 0.03%, and get the test mud. Put this instrument under the surface of the mud 850 mm, and measure the data curve of the mud density distribution changed over time as shown in Fig. 5. Table. 2 The Contrast Table of Measuring Value in 300 RPM and 600 RPM Test values

The values measured by six-speed rotary viscometer

The values measured by this instrument

Mud number

Ф600

Ф300

Ф600

Ф300

One

23

15

22.98

14.94

Two

42

35

41.88

35.00

three

58

49

57.69

48.87

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3:The test curve of the third senior 2:The test curve of the second senior 1:The test curve of the first senior

1

2

3 Time (min)

Fig. 5 The Curve of Density Distribution Experiment

7. Conclusions The automatic detection device on mud density or its distribution and mud rheology is suitable for automatic detection on mud density and viscosity fast, continuously and conveniently at the drilling site. Thus it overcomes the shortages of that error brought by conventional manual tests is bigger, that the number of mud sample is less, that the representative is not ideal, that the data should not be stored and the real-time performance is poor. The instrument can calculate that the density distribution of the mud in the tank or pool is uniform or not intelligently, judging whether the mud mixing is sufficient in real time; or deciding whether to need to improve the dispersion stability of mud by the distribution uniformity of mud. The basic data on viscosity can be used to calculate the rich rheological parameters in variety of flow pattern intelligently because of having the automatic checkout system of cell-type varying speed and analysis system. It makes the mud application indicators of viscosity accurate and comprehensive, and field workers can get the higher quality of analysis and evaluation. References [1] WU Xiaoming, HU Yule. The experimental principle and methods of drilling fluid and geotechnical engineering serous.Wu Han: 2010. [2] Gen Yanfeng, Yang Jinzhou. The research of measuring technology on near-bit engineering parameters based on the resistive strain gauge.2008.06. [3] Wang Lianxiang, Fang Dezhi. Mathematics handbook. Beijing :1977. [4] Yu Chengbo, Nie Chunyan. The principle and application of sensors. Wu Han: 2001.