optimize in-situ particle size distribution...

Optimize in-situ particle size distribution management to maximize drilling efficiency

Benjamin SmithAnjan Pandey, PhD June 2012

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Energy Industry: In-Line Particles and Droplets

Energy Suppliers

Asphaltenes, Emulsions, Gas Hydrates, Drilling Fluids, Inorganic

Precipitation

Introduction to FBRM® and PVM®

Asphaltenes

Gas Hydrates

Emulsions

Inorganic Precipitation

Return on Investment

Drilling Mud

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Outline

Introduction to FBRM® Probe Technology

Case Studies

- Detecting Shaker Screen Failure

- Solids Control Management

Conclusions

Typical Installations

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Typical Installations

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In-Situ Particle Characterization Tools

FBRM® TechnologyFocused Beam Reflectance Measurement

PVM® TechnologyParticle Vision and Measurement

FBRM® TechnologyFocused Beam Reflectance Measurement

10 µm droplets

TemperatureG400 #/sec 0‐20µm

TimeChord Length (µm)

FBRM tracks the rate and degree of change to particles and particle structures as they naturally exist in process - Specifications and method of measurement available at - www.mt.com/fbrm

PVM visualizes how particles and particle structures are changing as they naturally exit in process - Specifications and method of measurement available at www.mt.com/pvm

What is PVM®?

Particle Vision and Measurement

Inline imaging of Particles and Droplets: - Real time visualization at full process concentration

without sampling or dilution

Rapid Understanding, Immediate Results- PVM® provides a detailed understanding of complex

particle systems faster than any other method

PVM® allows us to see and understand particles and particle structures as they naturally exist in process

ISO 9001 CE

High resolution under extreme conditions PVM® provides the high resolution ability to see particles

under extreme conditions:in extremely viscous or opaque materials, or at extremely low or very high temperatures and pressureswhere sampling is impractical or impossible.

Water in Crude Oil with PVM® RE Window

PVM® measuring gas hydrates in Crude Oil

PVM tracking solvent extration

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200 RPM

1000 RPM

PVM V825 Ex – Inline process microscope

Specification Details

Overall Length 886mm (35 inches) not including conduitBack End Diameter 61mm (2.4 inches)

Fits inside 2-1/2 inch Sch 40 pipeBack End Materials Stainless 316L and 304Wetted Probe Tip 303mm long x 25mm diameterWetted Materials Probe and tip—Alloy C-22, Window—Sapphire

O-ring seals—Kalrez Compound 7075

Operating Temperature, Probe Back End

Maximum +85° C

Operating Temperature, Probe Tip

–20° C to +120° C

Conduit Temperature –5° C to +130° CConduit Length 10 meters (32.8 ft)

Probe-based for easy installation

Robust design for process environment

ATEX rated probe and enclosure

PVM V819 – Inline particle microscope

Probe-based for easy installation and compact, lightweight design for laboratory use

Highest resolution images of particles and droplets as they actually exist in the process

Class 1M laser product

SystemComponent Specification

Environmental (Temperature and Humidity)

Unit temperature: 5 to 30ºC (41 to 86ºF)Unit Humidity: 15%-85% Operating Humidity Conduit temperature: -60 to 120ºC (-76 to 248ºF) Probe Housing temperature: 5 to 30ºC (41 to 86ºF)Probe Tip temperature: -80 to 120ºC (-112 to 248ºF)

Imaging Field of view (nominal): 1075mm x 825mmResolution: 2 μmFocus Adjustment: Manual

Pressure Standard: Vacuum to 150psi (10bar)Probe Head Length: 163mm

Diameter: 69mmProbe Body Length: 400mm

Diameter: 19mmMaterial: Standard Alloy C-22 wetted probe tip, sapphire window

Conduit Length: 5m

Summary: FBRM G600

Application Scale: See next slideMaterial of Construction:

Probe Tip: SS 316L (AlloyC-22 Optional)Probe Window: SapphireProbe O-rings: Kalrez (TM Optional)

Probe Pressure Rating:

10 bar(up to 300 bar)

Probe Temperature Rating:

-10°C – 120°C-80°C – 150°C (custom)

Conduit Length: 15mMounting: See options on next slideCertification: CE, Class 1 Division 1,

ATEX, IEC ExProduct Page: www.mt.com/FBRMG600Datasheet:

FBRMPVMPSC

Introduction to FBRM®

Focused Beam Reflectance Measurement (FBRM®)

FBRM® is a probe based measurement that tracks the rate and degree of change to particles and particle structures as the particles naturally exist in process

FBRM ® is the standard method for tracking changes in particles and droplets – in process and in real time

Measure particles in process without the need for sampling and off-line analysis

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The FBRM® Method of Measurement

FBRM® Probe TubeFBRM® Probe Tube

SapphireWindowSapphireWindow

Beam splitterBeam splitter

Rotating opticsRotating optics

FBRM® Probe TubeFBRM® Probe Tube


Laser source fiberLaser source fiber



Focused beamFocused beamFBRM® Probe TubeFBRM® Probe Tube


Detection fiberDetection fiberLaser source fiberLaser source fiber



Focused beamFocused beamFBRM® Probe TubeFBRM® Probe Tube


Cutaway view of FBRM® In-process Probe

PVM® image illustrating the view from the FBRM® Probe Window

Probe installed in process stream

The FBRM® Method of MeasurementPVM® image illustrating the view from the FBRM® Probe WindowEnlarged view

Path of Focused Beam

Probe detects pulses of Backscattered light

And records measured Chord Lengths

The FBRM® Method of Measurement


Enlarged view

Thousands of Chord Lengths are measured each second to produce the FBRM® Chord Length Distribution :

Enlarged view


Tracking real-time changes with precision

0.5µm to 2000µm in a single unit without altering the system

Trended Statistics over time for specific user defined size ranges

No calibration necessary to measure fine and coarse particles

Unweighted Distribution

#/s <50 µm

#/s 50-1000 µm

Time (1 Measurement = 2 s)

FBRM comparison with Laser Diffraction

18SPE/IADC 125708

Screensand

Separators

The Drilling Mud CycleClean drilling mud is pumped down the drill pipe to the bit

Clean mud from the separators is returned to the drill

The drilling mud lifts fresh cuttings up the annulus

The mixture of mud and cuttings enters a series of screens and separators

Screensand

Separators

FBRM in the Drilling Mud Cycle

Lubrication of drill bit is impacted by particle distribution

Formulation particle distribution impacts stabilization of well, ability to remove debris, and fluid losses into the formation

Separation efficiency can be improved by monitoring particle distribution

A broken screen can be identified by in situ monitoring of particle distribution in the recycle loop

Stability of mud is critical to optimize production rates

Introduction to FBRM® and PVM® Probe Technologies

FBRM/PVM Case Studies



Conclusions

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Outline

MI SWACO Real-Time Fluids Monitoring

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FBRM® detects shaker screen tear/break without human monitoring.

Adding Cuttings to Drilling Mud

The mean particle dimension was monitored in situ and in real time

At key process time points large sand cuttings were added to simulate the production process upset of a screen break

FBRM® can quantitatively track the increase in particle dimension at these points

Laboratory

Unpublished results Francileide Gomes da Costa, Petrobras - CENPES

“Screen Break”Large particles

Stable Drilling Mud

“Screen Break”Large particles

Quantifying Changes During Cutting Additions

FBRM® distribution provides quantitative information about the particle distribution

As cuttings are added the distribution shifts to the right and the number of large particles counted increases

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Statistics Mean Sqr Wt <1006/22/2009

13:35 23.666/22/2009

13:44 26.196/22/2009

13:48 28.62

Increase in number of large particles

Increase in dimension


PVM® Images Validate FBRM® Distributions

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Increase in number of large particles

Increase in dimension

1:36:57

1:44:531:48:21


FBRM® Detects Screen Failures

185 ‐ 317µ

370 ‐ 632µ542 ‐ 1002µ

19 ‐ 63µ

54 ‐ 100µ

Example of screen failures causing increasing concentration of coarse particles

FBRM Off Shore Field Data Nov.2011





Conclusions

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Outline

FBRM enables users to achieve solids control management to maximize drilling efficiency and minimize upsets related to fluid losses or inefficient solids removal.

Use FBRM to target the correct particle distribution to plug formation (200-2000µm), lubricate and modify density (<75µm)


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Drilling into depleted reservoirs is challenging as the fracture strength of the reservoir is reduced due to pressure depletion from production

Optimum particle blends and size distributions are designed based on expected fracture and formation pore size.

The objectives of the yard trial were threefold:

i) Test the functionality of the FBRM instrument and its suitability to the rig environment

ii) Establish procedures for using the instrument as a tool to help manage the particle loading of the drilling fluid.

iii) Implement FBRM in a field trial off-shore in the North Sea

MI-SWACO STUDY

SPE/IADC 125708

Drilling Fluid Measurement – Field TrialRemote Real-Time Monitoring of Particle Size Distribution in Drilling Fluids During Drilling of a Depleted HTHP Reservoir

Ronaes et. al. SPE/IADC Conference, Bahrain, 2009

FBRM system ruggedized, C1/D1, IECEx, and ATEX –approved to withstand the harsh offshore rig environment.

FBRM probe directly installed in the flow loop (white arrow in the picture) to monitor circulating drilling fluid.

Offshore and onshore operators able to remotely monitor solid particulates while drilling depleted HTHP gas reservoir.

Drilling Fluid Measurement – Yard TrialRemote Real-Time Monitoring of Particle Size Distribution in Drilling Fluids During Drilling of a Depleted HTHP Reservoir


Yard Trial Set Up

- Cesium/Potassium brine-based drilling fluid

- 15 liters of circulating fluid volume in the test loop

- LCM blend components (refer to the table) used in the field added separately starting with

the coarsest particles

Yard Trial ResultsRemote Real-Time Monitoring of Particle Size Distribution in Drilling Fluids During Drilling of a Depleted HTHP Reservoir


Addition of CaCO3 (30)


Cou

nts/

s C

aCO

3 (2

00)

Cou

nts/

s C

aCO

3 (3

0)

Time (min)Time (min)

Cou

nts/

s C

aCO

3 (4

00)

Cou

nts/

s C

aCO

3 (1

000)



FBRM® monitored addition and dispersion of variably sized particles in opaque drilling fluid.

FBRM® detected very small concentration of coarse particles which were difficult to measure with offline instruments.

Continuous measurement of particle size and successful detection of changes in size distribution confirm FBRM® effectiveness for good solids control management during drilling operation.

Field Trial ResultsRemote Real-Time Monitoring of Particle Size Distribution in Drilling Fluids During Drilling of a Depleted HTHP Reservoir


FBRM® C90 is sensitive to the amount of coarse particles.

FBRM ® C90 increases when bottoms up circulation was performed at 19:30 due to removal of coarse well cuttings.

FBRM ® is sensitive to changes in solid particle size distribution, solids concentration, mechanical attrition of particles, and loss of solid particles during drilling fluid circulation.

Rapid detection of changes in solids enable operators to optimize drilling fluid particle distribution for wellbore strengthening and formation bridging.

Field Trial ResultsRemote Real-Time Monitoring of Particle Size Distribution in Drilling Fluids During Drilling of a Depleted HTHP Reservoir


Between 09:00 and 11:50 the drilling fluid returns were run across three shakers dressed with 33% 10-mesh, 33% 20-mesh and 33% 40-mesh screens, thus the major part of Graphite (233 – 683 μm) and CaCO3 (632 – 2,000 μm) were screened out

The reduction in particle size is well described by the FBRM C90 parameter in this period.

Rapid detection of changes in solids enable operators to optimize drilling fluid particle distribution for wellbore strengthening and formation bridging.





Conclusions

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Outline

Conclusions

FBRM® and PVM® enable scientists and engineers to understand, optimize and control particle droplet and particle distributions in complex multiphase pipeline flow.

The rate and degree of change to particles by size class can be quickly measured and downstream fluid losses can be minimized by adjusting upstream solid additions

A screen tear can be detected in real time improving the process consistency, safety, and reducing labor resource requirements.

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References

Gas HydratesEmmanuel Delle-Case, University of Tulsa. Greaves et al., Chemical Engineering Science 63 (2008) 4570 – 4579. Taylor, C. J. Master thesis, Colorado School of Mines, Golden, CO, 2006. Darbouret et al, Proc.Int.Conf. Gas Hydrates Vancouver, July 6-10, 2008. Hung, L. et. al., XII Congres de la Societe Francaise, France, 2009.Boxall, J. et. al., Proc. of the 6th Intl. Conf. on Gas Hydrates, Canada, 2008.Hung, L. et. al., Proc. of the 6th Intl. Conf. on Gas Hydrates, Canada, 2008Turner, D. et. al., Proc. of the 6th Intl. Conf. on Gas Hydrates, Canada, 2008

AsphaltenesCalles, J. et. al., Energy Fuels 22(2): 763-769 (2008).Marugan, J. et. al., Energy Fuels 23 : 1155-1161(2009).Dufour et. al. Energy Fuels, 2009, 23 (3), 1155-1161. Cajaiba et al, International Process Development Conference, Arosa, Switzerland, June 17 2009.

Oil-Water Emulsions

Boxall, J. et. al., Ind. Eng. Chem. Res. 2010 (Published Online).Westra, R.W. et al., International Petroleum Technology Conference 14917.

Partial List of FBRM® Users Petroleum Petrobras Exxon-Mobile Shell Chevron Conoco Phillips BP Total Statoil MI Swaco, Schlumberger Saudi Aramco

Mining Rio Tinto CSIRO Aughinish Alumina Alcoa Nalco

Government Agencies: Cogema (France) Oak Ridge National Laboratory (USA) Pacific Northwest National Labs (Battelle) Los Alamos National Labs (USA)

Specialty Chemical: Nalco Akzo-Nobel BASF Dow Chemical Dupont Exxon Mobil Monsanto Procter & Gamble

Research and Consulting Services:• Sintef (Norway)• IFP (France)• Southwest Research Institute • Eni-Technologie

Universities:• Universidade Federal do Rio de Janeiro• Universidade de Sao Paulo • University of Alberta• The University of Calgary• China University of Petroleum• Colorado School of Mines• Georgia Tech • University of Tulsa• MIT (Massachusetts Institute of Technology)• University College Dublin (Ireland)

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Questions and AnswersFor further information on products and applications:

Visit us at www.mt.com/formulations

OR

Email us at [email protected]

OR

Call us + 1.410.910.8500

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Don’t miss the 17th International Process Development Conference - May 16 to 19, 2010 in Baltimore, MD, USA – www.mt.com/ipdc

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